CN210536494U - Power conversion device - Google Patents

Abstract

The utility model provides a can realize miniaturized power conversion device. The power conversion device is provided with: a reactor; a power line connected to the reactor; and a shield member having a contact portion that contacts the reactor and a shield portion that extends along the power line and shields electric waves emitted from the power line.

Description

Power conversion device

Technical Field

The utility model relates to a power conversion device.

Background

In recent years, in order to extend a cruising distance, an in-vehicle power conversion device has been integrated. Accordingly, in order to cool the small-sized and heat-generating electric power components, a structure is adopted in which the electric power components are mounted on both surfaces of the cooler.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2016-220344

SUMMERY OF THE UTILITY MODEL

Problem to be solved by utility model

In the above-described configuration, since it is necessary to pass the power cable and the signal cable, which connect the circuits provided above and below the cooler to each other, through the through hole penetrating the cooler in the up-down direction in a close state, there is a problem in that noise generated from the power cable affects the function of the signal cable.

In order to solve the above problem, patent document 1 discloses a structure in which a shield film for preventing noise from flowing out is provided in a cable itself. However, the structure described in patent document 1 has a problem that the size of the cable increases, and the size of the power conversion device increases accordingly.

An object of the utility model is to provide a can realize miniaturized power conversion device.

Means for solving the problems

The utility model discloses a form is power conversion device, and it possesses: a reactor; a power line connected to the reactor; and a shield member having a contact portion that contacts the reactor and a shield portion that extends along the power line and shields electric waves emitted from the power line.

Alternatively, the power conversion device may further include a case that is divided into a first space and a second space by a partition member, the reactor may be accommodated in the first space, and the power line and the shield member may be provided on the partition member and inserted into a hole that communicates the first space with the second space.

Optionally, a signal line is inserted into the hole, the shield member being interposed between the power line and the signal line.

Alternatively, the reactor is housed in a case, a heat-dissipating resin is filled in a gap between the reactor and the case, and the shield member is in contact with the heat-dissipating resin.

Alternatively, the reactor may include an upper first core and a lower second core, and the shield member may be in contact with the upper first core and in contact with the heat dissipating resin. Optionally, the shield member is not in contact with any one of the lower surface of the lower second core and the outer shell.

Effect of the utility model

According to the utility model discloses, can realize power conversion equipment's miniaturization.

Drawings

Fig. 1 is a circuit diagram showing a configuration of a power supply device according to an embodiment.

Fig. 2 is a diagram showing a configuration of a power supply device according to an embodiment.

Fig. 3A is a diagram showing a structure of a low-voltage substrate according to an embodiment.

Fig. 3B is a diagram showing a structure of a low-voltage substrate according to the embodiment.

Fig. 3C is a diagram showing a structure of the low-voltage substrate according to the embodiment.

Fig. 3D is a diagram showing a structure of a low-voltage substrate according to a modification.

Fig. 3E is a diagram showing a structure of a control board according to a modification.

Fig. 4A is a perspective view showing a transformer and a configuration around the transformer according to the embodiment.

Fig. 4B is a perspective view showing the structure of the transformer shield according to the embodiment.

Fig. 4C is a diagram showing a transformer.

Fig. 4D is a cross-sectional view 4D-4D of fig. 4C.

Fig. 4E is a cross-sectional view 4E-4E of fig. 4D.

Fig. 5A is a diagram for explaining a common structure of the capacitor.

Fig. 5B is a diagram for explaining a common structure of the capacitor.

Fig. 5C is a diagram for explaining a common structure of the capacitor.

Fig. 6A is a perspective view showing a coil and a configuration around the coil of a DC/DC converter (DC/DC converter) according to an embodiment.

Fig. 6B is a diagram showing a coil.

Fig. 6C is a cross-sectional view of 6C-6C of fig. 6B.

Fig. 7A is a perspective view showing the current sensor and the configuration of the periphery thereof according to the embodiment.

Fig. 7B is a diagram showing a current sensor.

Fig. 7C is a cross-sectional view of 7C-7C of fig. 7B.

Fig. 7D is a cross-sectional view of fig. 7B taken along line 7D-7D.

Description of the reference numerals

1 Power supply device

2 external power supply

3 Battery

4 load

5 electric machine

5a bus bar

5b bus bar

5c bus bar

5d signal line

6 first circuit part

7 second circuit part

8 primary side circuit

10 AC filter part

20 charger

21 rectifying part

22 power factor improving section

22a coil

22b switching element

22c diode

23 capacitor

24 DC/DC converter (DC/DC converter)

24a inverter

24b transformer

24c secondary side rectification circuit

24d switching element

24e power transmission coil

24f power receiving coil

24g switching element

30 capacitor

40 DC/DC converter

41 switching element

42 coil

42a upper core body

42b lower core body

42c coil body

43 capacitor

50 capacitor

60 power conversion unit

70 first control part

80 second control part

90 current sensor

91 main body part

92 fixed part

93 first hole

94 second hole

95 third hole

100 case

101 partition member

101a first cover part

101b second cover part

102 first space

103 second space

104 heat sink

105 holes

110 AC filter substrate

120 high voltage substrate

130. 130A low voltage substrate

131 connector

132. 132A wiring pattern

133. 133A wiring pattern

134. 134A wiring pattern

135. 135A wiring pattern

136 connector

137 first substrate

138 second substrate

139 third substrate

140 power line

150 signal line

160 control substrate

161 connector

162 wiring pattern

163 wiring pattern

164 wiring pattern

200 transformer shell

201 side wall

202 space

210 transformer shield

211 bottom wall part

212 first side wall portion

213 second side wall part

214 third sidewall portion

215 opening part

216 first fixed part

217 fourth side wall part

218 second fixing part

219 intermediate section

220 fifth side wall part

221 sixth side wall part

231 upper core body

232 lower core body

233 coil

240 heat-dissipating resin

300 base

310 casing

311 side wall

311a first side wall

311b second side wall

311c third side wall

311d fourth side wall

312 space

313 bottom surface

314 bead

314a first rib

314b second rib

314c third rib

315 Heat dissipating resin

320 power line

321 power line

400 wall part

401 opening part

402 fixed part

410 wall part

411 first wall part

412 second wall portion

413 third wall part

414 fourth wall part

415 third space

420 wall part

430a bus bar

430b bus bar

430c bus bar

Detailed Description

Next, a power supply device ("an example of a power converter") according to an embodiment of the present invention will be described in detail with reference to the drawings. The embodiments described below are examples, and the present invention is not limited to these embodiments.

(Overall Structure of Power supply device)

The overall configuration of the power supply apparatus 1 will be described with reference to fig. 1. Fig. 1 is a circuit diagram showing the configuration of a power supply device 1.

The power supply device 1 is mounted on a vehicle such as an electric vehicle. The power supply device 1 charges the battery 3 with power supplied from the external power supply 2, and supplies power from the battery 3 to at least one of the load 4 and the motor 5.

The battery 3 is, for example, a low-voltage (e.g., 48V) rated battery that does not require insulation with respect to the body of the vehicle. The battery 3 is, for example, a lithium ion battery. The load 4 is an electronic device driven by a low voltage (e.g., 12V). The motor 5 is a three-phase alternating current motor driven by a low voltage (e.g., 48V). The motor 5 is a motor for running drive of the vehicle.

The power supply device 1 includes: ac filter unit 10, charger 20, DC/DC converter unit 40, capacitor 50, power converter unit 60, first control unit 70, and second control unit 80. The ac filter unit 10, the charger 20, the DC/DC converter unit 40, the capacitor 50, the power converter unit 60, the first control unit 70, and the second control unit 80 are housed inside a case 100, and the case 100 is connected to a vehicle body of a vehicle on which the power supply device 1 is mounted.

The ac filter unit 10 reduces noise entering from the external power supply 2 and noise flowing out to the external power supply 2. The ac filter unit 10 includes a coil, a capacitor, and the like.

The charger 20 converts electric power of a first voltage (for example, 100V) supplied from the external power supply 2 as an ac power supply into electric power of a second voltage (for example, 48V) lower than the first voltage, and outputs the electric power to the battery 3. Charger 20 includes rectifying unit 21, power factor improving unit 22, capacitor 23, and DC/DC converter 24.

The rectifier 21 full-wave rectifies the ac power from the ac filter 10, converts the rectified power into dc power, and outputs the dc power to the power factor corrector 22. The rectifying unit 21 is a diode bridge circuit including four diodes.

The power factor improving unit 22 has a function of improving the power factor of the electric power from the rectifying unit 21. The power factor correction unit 22 includes a coil 22a, a switching element 22b, and a diode 22 c. Although omitted in fig. 1, the power supply device 1 has two power factor correction units 22 connected in parallel between the rectifying unit 21 and the capacitor 23. Thus, the power factor correction unit 22 constitutes an interleaved (interleave) type power factor correction circuit.

The capacitor 23 is connected to the output side of the power factor correction unit 22, and smoothes the dc power from the power factor correction unit 22. Since the voltage of the dc power is boosted by the power factor correction unit 22, the capacitor 23 is a relatively large-capacity capacitor.

The DC/DC converter 24 is a circuit that converts the DC power from the power factor corrector 22 into a voltage that can be charged in the battery 3. The DC/DC converter 24 includes an inverter 24a, a transformer 24b, and a secondary-side rectifier circuit 24 c.

The inverter 24a converts the dc power from the power factor correction unit 22 into ac power and outputs the ac power to the transformer 24 b. The inverter 24a has four switching elements 24 d.

The transformer 24b transforms the voltage of the ac power from the inverter 24a and outputs the transformed voltage to the secondary-side rectifier circuit 24 c. The transformer 24b has a power transmission coil 24e connected to the output side of the inverter 24a and a power reception coil 24f connected to the input side of the secondary side rectification circuit 24 c.

The secondary-side rectifier circuit 24c is a circuit that converts ac power from the transformer 24b into dc power. The secondary-side rectifying circuit 24c has four switching elements 24 g.

The DC/DC converter 40 converts the DC power of the second voltage (e.g., 48V) output from the battery 3 into a third voltage (e.g., 12V) that can be supplied to the load 4. The DC/DC converter 40 includes a capacitor 30 disposed on the input side, switching elements 41 (two), a coil 42, and a capacitor 43 disposed on the output side.

Capacitor 50 is disposed on the input side of power conversion unit 60. The function of the capacitor 50 will be described later.

The power conversion unit 60 converts the dc power of the second voltage into ac power. The power conversion unit 60 is a three-phase bridge inverter circuit and has a plurality of switching elements. A current sensor 90 is provided on the output side of the power conversion unit 60.

The first control unit 70 controls the operation of the charger 20 by on/off controlling the switching element 22b of the power factor correction unit 22, the switching element 24d of the inverter 24a, and the switching element 24g of the secondary side rectifier circuit 24 c. That is, under the control of the first control section 70, the ac power of the first voltage supplied from the external power supply 2 is converted into the dc power of the second voltage by the charger 20, and is charged into the battery 3.

The first control unit 70 controls the operation of the DC/DC converter unit 40 by on/off controlling the switching element 41 of the DC/DC converter unit 40. That is, under the control of the first control section 70, the DC power of the second voltage is converted into the DC power of the third voltage by the DC/DC conversion section 40, and is output to the load 4.

The second control unit 80 controls the operation of the power conversion unit 60 by on-off controlling the switching elements of the power conversion unit 60. That is, under the control of the second control unit 80, the dc power of the second voltage supplied from the battery 3 is converted into the three-phase ac power of the second voltage by the power conversion unit 60, and is output to the motor 5.

The first control unit 70 and the second control unit 80 can communicate with the vehicle control device through a connector provided in the casing 100, and control each unit of the power supply device 1 under the control of the vehicle control device. Further, since the first control unit 70 and the second control unit 80 operate at a low voltage, insulation from the vehicle body is not required.

(Structure of Power supply device)

Next, the structure of the power supply device 1 will be described with reference to fig. 2. Fig. 2 is a diagram showing the configuration of the power supply device 1. Fig. 2 schematically shows the configuration of the power supply device 1, and some components and wirings not directly related to the description are omitted. The Z-axis is depicted in fig. 2 for ease of understanding. The positive direction of the Z axis (upward direction in fig. 2) is defined as the + Z direction.

The power supply device 1 has a casing 100. The housing 100 has: a partition member 101 extending on a plane (hereinafter, referred to as an "XY plane") orthogonal to the Z axis, a first cover member 101a provided on the-Z direction side of the partition member 101, and a second cover member 101b provided on the + Z direction side of the partition member 101.

In the present embodiment, the partition member 101, the first cover member 101a, and the second cover member 101b are all made of aluminum. The first cover member 101a has a + Z-direction side opening. The second cover member 101b has a-Z-direction side opening. The first cover member 101a and the second cover member 101b are fixed (e.g., screwed) to the partition member 101.

The ac filter unit 10, the rectifier unit 21, the power factor improving unit 22 (the coil 22a, the switching element 22b, and the diode 22c), the capacitor 23, the inverter 24a, and the transformer 24b in the charger 20 are disposed in the first space 102 surrounded by the partition member 101 and the first cover member 101 a.

The ac filter unit 10, the rectifier unit 21, the power factor improving unit 22, the capacitor 23, the inverter 24a, and the transformer 24b in the charger 20 are portions to which the first voltage is applied. Hereinafter, a portion to which the first voltage is applied may be referred to as "first circuit portion 6" (see fig. 1). The rectifier 21, the power factor correction unit 22, the capacitor 23, the inverter 24a, and the transformer 24b in the charger 20 may be referred to as a "primary circuit 8" (see fig. 1).

Each element constituting the ac filter unit 10 is mounted on the + Z side surface of the ac filter substrate 110 extending on the XY plane. The ac filter substrate 110 is a resin substrate.

The elements constituting the rectifying unit 21, the switching element 22b and the diode 22c of the power factor correction unit 22, and the inverter 24a are mounted on the + Z side surface of the high voltage board 120 extending on the XY plane. The capacitor 23 is mounted on the-Z side of the high voltage substrate 120. The high voltage substrate 120 is a resin substrate. The ac filter substrate 110 is electrically connected to the high voltage substrate 120.

The high-voltage substrate 120 is disposed on the-Z direction side of the partition member 101 with a gap from the partition member 101. The ac filter substrate 110 is disposed on the-Z direction side of the high voltage substrate 120 with a gap from the high voltage substrate 120.

The coil 22a of the power factor improving section 22 is disposed with a predetermined gap from the-Z side surface of the partition member 101. The high voltage substrate 120 is electrically connected to the coil 22 a. The transformer 24b is disposed with a predetermined gap from the-Z side surface of the partition member 101. The high voltage substrate 120 is electrically connected to the transformer 24 b.

The secondary-side rectifying circuit 24c, the DC/DC converter 40, the capacitor 50, the power converter 60, the first controller 70, and the second controller 80 of the charger 20 are provided in a second space 103 surrounded by the partition member 101 and the second cover member 101 b.

The secondary-side rectifying circuit 24c, the DC/DC converter 40, the capacitor 50, the power converter 60, the first controller 70, and the second controller 80 of the charger 20 are applied with the second voltage. Hereinafter, a portion to which the second voltage is applied may be referred to as "second circuit portion 7" (see fig. 1).

The insulation level in the first space 102 and the insulation level in the second space 103 are different from each other. Specifically, the insulation level in the first space 102 is higher than the insulation level in the second space 103.

The secondary-side rectifying circuit 24c, the DC/DC converter 40, the capacitor 50, and the power converter 60 constituting the charger 20 are mounted on the + Z side surface of the low-voltage board 130. The low-voltage substrate 130 is an aluminum substrate, and the + Z side surface of the low-voltage substrate 130 is covered with an insulating layer of resin.

In addition, a wiring pattern for electrically connecting the elements is printed on the surface of the insulating layer. The wiring pattern formed on the low-voltage substrate 130 will be described later. the-Z side of the low voltage substrate 130 is in direct contact with the + Z side of the partition member 101. This enables the low-voltage side elements through which a large current flows to be appropriately cooled.

The partition member 101 is provided with a heat sink 104. Further, the partition member 101 is provided with a hole 105 penetrating in the Z direction. The first circuit portion 6 and the second circuit portion 7 are electrically connected by a power line 140 disposed through the through-hole 105. Specifically, the transformer 24b and the secondary-side rectifier circuit 24c are electrically connected by power lines 140 arranged through the through-holes 105.

The elements constituting the first control unit 70 and the elements constituting the second control unit 80 are mounted on the + Z side surface of the control board 160 extending on the XY plane. The control substrate 160 is a resin substrate. The control board 160 is disposed on the + Z direction side of the low voltage board 130 with a gap from the low voltage board 130.

The first control unit 70 is electrically connected to the switching element 22b and the inverter 24a via a signal line 150 disposed through the through-hole 105.

As described above, in the present embodiment, the primary-side circuit 8 of the charger 20 to which the first voltage is applied is housed in the first space 102, and the secondary-side rectifier circuit 24c of the charger 20 to which the second voltage lower than the first voltage is applied is housed in the second space 103.

In addition, according to the present embodiment, the first circuit portion 6 to which the first voltage is applied is housed in the first space 102, and the second circuit portion 7 to which the second voltage lower than the first voltage is applied is housed in the second space 103.

Thus, elements on the high-voltage side, which require high insulation, can be collectively disposed in the first space 102, and elements on the low-voltage side, which require high heat dissipation, can be collectively disposed in the second space 103.

According to the present embodiment, by appropriately arranging the respective elements in accordance with the necessity of insulation and the necessity of heat dissipation, the insulation structure and the heat dissipation structure can be appropriately configured, and the power supply device 1 can be downsized.

In addition, according to the present embodiment, the first control unit 70 that controls the primary-side circuit 8 is housed in the second space 103. Therefore, it is possible to suitably suppress the excessive insulation of the elements constituting the first control section 70.

In addition, according to the present embodiment, the elements on the low-voltage side, which flow a large current and have high heat generation properties, are collectively mounted on the aluminum low-voltage substrate 130 having excellent heat dissipation properties. Therefore, these elements can be appropriately cooled.

The low-voltage substrate 130 is disposed in direct contact with the partition member 101 having the heat sink 104 and having excellent heat dissipation properties. Therefore, the low-voltage side elements that have a high heat generation property and a large current can be cooled more appropriately.

Further, according to the present embodiment, since the elements on the high voltage side are collectively arranged in the first space 102 and the elements on the low voltage side are collectively arranged in the second space 103, it is possible to suitably suppress the influence of noise generated on the high voltage side on the low voltage side.

In particular, in the present embodiment, the power supply device 1 has a partition member 101 that partitions a first space 102 and a second space 103, and the partition member 101 has a heat sink 104. This makes it possible to separate the first space 102 on the high voltage side and the second space 103 on the low voltage side.

Therefore, it is possible to appropriately suppress the influence of noise generated on the high voltage side on the low voltage side. Further, since the impedance can be increased by the partition member 101 and the heat sink 104, it is possible to further appropriately suppress the influence of noise generated on the high voltage side on the low voltage side.

(distribution structure in Low Voltage substrate)

Next, a wiring pattern (power distribution structure) on the low-voltage substrate 130 will be described with reference to fig. 3A, 3B, and 3C. Fig. 3A, 3B, and 3C are diagrams illustrating the structure of the low voltage substrate 130. The X, Y, and Z axes are depicted in fig. 3A, 3B, and 3C for ease of understanding. The Z-axis is the same as the Z-axis of fig. 2. The positive direction of the X axis is defined as the + X direction, and the positive direction of the Y axis is defined as the + Y direction. In fig. 3A, 3B, and 3C, the configuration that is not directly related to the description is omitted.

As described above, the low voltage substrate 130 is a metal substrate such as an aluminum substrate or a copper substrate. The low-voltage board 130 is directly mounted on and fixed to the + Z side surface of the partition member 101 (see fig. 2). The + Z side surface of the low-voltage substrate 130 is covered with an insulating layer made of resin.

Elements of the secondary-side rectifier circuit 24c, elements of the DC/DC converter 40, elements of the capacitor 50, and elements of the power converter 60 are mounted on the + Z side surface of the low-voltage substrate 130.

At an end portion in the-X direction of the low-voltage board 130, a connector 131 for power output to the battery 3 and power input from the battery 3 is provided. The connector 131 is a common connector for the DC/DC converter 40 and the power converter 60.

The secondary-side rectifying circuit 24c of the charger 20 is provided on the + Y direction side of the connector 131 and near the end of the low-voltage board 130 in the-X direction. The DC/DC converter 40 is provided on the + X direction side of the secondary-side rectifier circuit 24c and near the end of the low-voltage board 130 in the + Y direction. Capacitor 50 and power conversion unit 60 are provided on the-Y direction side of connector 131.

The connector 131 is electrically connected to the secondary-side rectifier circuit 24c, the DC/DC converter 40, and the power converter 60 by a wiring pattern printed on the surface of the insulating layer of the low-voltage substrate 130.

The wiring pattern 132 extends from the connector 131 in the + X direction. That is, the first end of the wiring pattern 132 is connected to the connector 131. The wiring pattern 133, the wiring pattern 134, and the wiring pattern 135 are branched from the second end of the wiring pattern 132.

The wiring pattern 133 is connected to the secondary-side rectifier circuit 24 c. That is, the first end of the wiring pattern 133 is connected to the second end of the wiring pattern 132, and the second end of the wiring pattern 133 is connected to the output side of the secondary-side rectifier circuit 24 c. Further, a power line 140 (see fig. 2) electrically connecting the input side of the secondary side rectifier circuit 24c and the transformer 24b extends in the + Z direction from the secondary side rectifier circuit 24 c.

The wiring pattern 134 is connected to the DC/DC converter 40. That is, the first end of the wiring pattern 134 is connected to the second end of the wiring pattern 132, and the second end of the wiring pattern 134 is connected to the input side of the DC/DC converter 40. Further, a connector 136 for outputting the power from the DC/DC converter 40 to the load 4 is provided at an end portion of the low voltage board 130 in the + Y direction.

The wiring pattern 135 is connected to the power conversion unit 60 via the capacitor 50. That is, the first end of the wiring trace 135 is connected to the second end of the wiring trace 132, and the second end of the wiring trace 135 is connected to the input side of the power conversion unit 60. Further, a power line that outputs the electric power from the power conversion unit 60 to the motor 5 extends from the power conversion unit 60 in the + Z direction.

Fig. 3B shows an operation state in which the battery 3 is charged with electric power from the external power supply 2 and the load 4 is supplied with electric power from the external power supply 2. The current a1[ a ] output from the secondary-side rectifier circuit 24c of the charger 20 flows through the wiring pattern 133. Current a2[ a ] input to DC/DC converter 40 flows through wiring pattern 134. A current obtained by subtracting the current output to the DC/DC converter 40 from the current output from the secondary-side rectifier circuit 24c of the charger 20 flows in the wiring pattern 132. That is, a current of (A1-A2) [ A ] flows through the wiring pattern 132.

Fig. 3C shows an operation state in which the power from the battery 3 is supplied to the load 4 and the motor 5. Current a2[ a ] input to DC/DC converter 40 flows through wiring pattern 134. Current a3[ a ] input to power conversion unit 60 flows through wiring pattern 135. A current obtained by adding the current input to the DC/DC converter unit 40 and the current input to the power converter unit 60 flows through the wiring pattern 132.

That is, in the operating state in which the power from the battery 3 is supplied to the load 4 and the motor 5, a large current of (a2+ A3) [ a ] flows through the wiring pattern 132. Therefore, the amount of heat generation is large particularly in the wiring pattern 132.

In the present embodiment, the wiring pattern 132, the wiring pattern 133, the wiring pattern 134, and the wiring pattern 135 are all provided on the aluminum low-voltage substrate 130. Therefore, even when a large current flows through the wiring pattern 132 and the amount of heat generated in the wiring pattern 132 is large, the wiring pattern 132 can be cooled appropriately.

In the present embodiment, the secondary-side rectifier circuit 24c, the DC/DC converter 40, the capacitor 50, and the power converter 60 are also disposed on the low-voltage board 130. Therefore, the secondary-side rectifier circuit 24c, the DC/DC converter 40, the capacitor 50, and the power converter 60 can be appropriately cooled.

In particular, the secondary-side rectifier circuit 24c, the DC/DC converter 40, the capacitor 50, and the power converter 60 are included in the second circuit portion 7 on the low voltage side, and therefore generate a large amount of heat during operation. According to the present embodiment, even when the DC/DC converter 40 and the power converter 60 operate simultaneously, for example, heat generated in the wiring pattern 132, the wiring pattern 134, the wiring pattern 135, the DC/DC converter 40, the capacitor 50, and the power converter 60 can be appropriately dissipated from the low-voltage substrate 130.

As described above, in the present embodiment, the power supplied via the connector 131 is distributed to the wiring patterns 132, 134, and 135 of the DC/DC converter unit 40 and the power converter unit 60, and is formed on the aluminum low-voltage substrate 130 having high heat dissipation performance.

Therefore, even when the DC/DC converter 40 and the power converter 60 operate simultaneously, the heat generated in the wiring patterns 132, 134, and 135 can be appropriately dissipated from the low-voltage substrate 130.

In the above-described embodiment, the example in which the secondary-side rectifier circuit 24c, the DC/DC converter 40, the capacitor 50, and the power converter 60 are mounted on the low-voltage board 130 has been described, but the present invention is not limited thereto. A modified example of the power distribution structure will be described below.

(modification of distribution Structure in Low-Voltage substrate)

A modification of the power distribution structure will be described in detail with reference to fig. 3D. Fig. 3D is a diagram showing a wiring structure of the low-voltage substrate 130A according to a modification. The X, Y, and Z axes are depicted in fig. 3D for ease of understanding. The X, Y, and Z axes are the same as those in fig. 3A to 3C.

In the modification, the difference from the above embodiment is that: the secondary-side rectifier circuit 24c, the DC/DC converter 40, and the power converter 60 are not mounted on the low-voltage board 130A. The same reference numerals are given to the same components as those of the above-described embodiment, and their names and functions are also the same. Therefore, detailed description thereof will be omitted.

The low-voltage substrate 130A is, for example, an aluminum substrate. The low-voltage substrate 130A is directly mounted on and fixed to the + Z side surface of the partition member 101 (see fig. 2). The + Z side surface of the low-voltage substrate 130A is covered with an insulating layer.

The secondary-side rectifier circuit 24c of the charger 20 is mounted on a first substrate 137 that is separate from the low-voltage substrate 130A. The DC/DC converter 40 is mounted on a second substrate 138 that is separate from the low-voltage substrate 130A. The power conversion unit 60 is mounted on a third substrate 139 that is separate from the low-voltage substrate 130A.

A connector 131 is provided at an end of the low voltage substrate 130A in the-X direction. The wiring pattern 132A extends from the connector 131 in the + X direction. That is, the first end of the wiring trace 132A is connected to the connector 131. The second end of the wiring pattern 132A branches into the wiring pattern 133A, the wiring pattern 134A, and the wiring pattern 135A.

That is, the wiring pattern 132A, the wiring pattern 133A, the wiring pattern 134A, and the wiring pattern 135A are all provided on the low voltage substrate 130A.

The wiring pattern 133A is electrically connected to the secondary-side rectifier circuit 24c mounted on the first substrate 137. The power line electrically connecting the low-voltage board 130A and the first board 137 may be a flexible wire or a rigid body such as a bus bar.

The wiring pattern 134A is electrically connected to the DC/DC converter 40 mounted on the second substrate 138. The power line electrically connecting the low-voltage substrate 130A and the second substrate 138 may be a flexible wire or a rigid body such as a bus bar.

The wiring pattern 135A is electrically connected to the power converter 60 mounted on the third substrate 139. The power line electrically connecting the low-voltage substrate 130A and the third substrate 139 may be a flexible wire or a rigid body such as a bus bar.

As described above, in the modification, the wiring pattern 132A is formed on the aluminum low-voltage substrate 130A having high heat dissipation performance. Therefore, even when a large current flows through the wiring pattern 132A and the amount of heat generated in the wiring pattern 132A is large, the wiring pattern 132A can be cooled appropriately.

In the above-described modification, the secondary-side rectifier circuit 24c, the DC/DC converter 40, and the power converter 60 are mounted on separate substrates, but the present invention is not limited thereto. For example, the DC/DC converter 40 and the power converter 60 may be mounted on the same substrate, or the power converter 60 having a large amount of heat generation may be mounted on a low-voltage substrate.

(Power distribution structure in control substrate)

A wiring pattern (power distribution structure) in the control board 160 will be described with reference to fig. 3E. Fig. 3E is a diagram showing the structure of the control board 160. The X, Y, and Z axes are depicted in fig. 3E for ease of understanding. The X, Y, and Z axes are the same as those in fig. 3A to 3D. In fig. 3E, a structure that is not directly related to the description is omitted.

As described above, the control substrate 160 is a resin substrate. The elements of the first control unit 70 and the elements of the second control unit 80 are mounted on the + Z side surface of the control board 160. A connector 161 for inputting power and a control signal from the outside is provided at an end portion of the control board 160 in the + Y direction. The connector 161 is a common connector for the first control unit 70 and the second control unit 80.

The first control unit 70 is provided near an end of the control board 160 in the + Y direction. The second control portion 80 is provided near an end portion of the control board 160 in the-Y direction. The connector 161 is electrically connected to the first control unit 70 and the second control unit 80 by wiring patterns printed on the surface of the control board 160.

The wiring pattern 162 extends from the connector 161 in the-Y direction. That is, the first end of the wiring trace 162 is connected to the connector 161. The wiring pattern 162 is branched from the second end into a wiring pattern 163 and a wiring pattern 164.

The wiring pattern 163 is connected to the first control unit 70. That is, the first end of the wiring trace 163 is connected to the second end of the wiring trace 162, and the second end of the wiring trace 163 is connected to the first controller 70.

The wiring pattern 164 is connected to the second control section 80. That is, the first end of the wiring trace 164 is connected to the second end of the wiring trace 162, and the second end of the wiring trace 164 is connected to the second controller 80.

The current a4[ a ] input to the first control unit 70 flows through the wiring pattern 163. The current a5[ a ] input to the second controller 80 flows through the wiring pattern 164. That is, a current of (a4+ a5) [ a ] flows through the wiring pattern 162.

In the present embodiment, power from the outside is supplied to the first controller 70 and the second controller 80 via the wiring pattern 162 on the control board 160 and the wiring patterns 163 and 164 branched from the wiring pattern 162.

Therefore, wiring processing is not required in the case, and the power supply device 1 can be downsized.

(Transformer and its peripheral structure)

The structure of the transformer 24B and its surroundings will be described with reference to fig. 4A, 4B, 4C, 4D, and 4E. Fig. 4A to 4E depict the X axis, Y axis, and Z axis for easy understanding. The X, Y, and Z axes are the same as those in fig. 3A to 3E. In fig. 4A to 4E, a configuration not directly related to the description is omitted.

Fig. 4A is a perspective view showing the structure of the transformer 24b and its periphery. As shown in fig. 4A, a transformer case 200 made of resin and formed integrally with the base of the high-voltage board 120 (see fig. 2) is provided on the-Z side surface of the partition member 101. The transformer case 200 is open at both ends in the-Z direction and the + Z direction. The end of the transformer case 200 in the + Z direction is fixed to the partition member 101 by adhesion. Thus, the box-shaped transformer case 200 is configured with the partition member 101 as the bottom surface and with only the upper surface (surface in the (-Z direction)) opened. The transformer 24b is accommodated in the transformer housing 200.

The transformer shield 210 is disposed so as to cover the-Z side of the transformer 24 b. The transformer shield 210 will be described in detail below with reference to fig. 4B. Fig. 4B is a perspective view showing the structure of the transformer shield 210.

The transformer shield 210 is a thin plate-like member (e.g., aluminum material) having good electrical and thermal conductivity. The transformer shield 210 has: a bottom wall portion 211 extending on the XY plane, a first side wall portion 212 extending from the end portion of the bottom wall portion 211 in the + Y direction to the + Z direction, and a second side wall portion 213 extending from the end portion of the bottom wall portion 211 in the-Y direction to the + Z direction.

Further, transformer shield 210 has third sidewall 214 extending from the end of bottom wall 211 in the-X direction to the + Z direction. The opening 215 is provided so as to straddle the end of the bottom wall 211 in the-X direction and the end of the third side wall 214 in the-Z direction.

A first fixing portion 216 protrudes in the-X direction from an end portion in the + Z direction near the end portion in the + Y direction of the third side wall portion 214. The transformer shield 210 is fixed to the transformer case 200 and the partition member 101 at the first fixing portion 216 (see fig. 4A).

A fourth side wall portion 217 extending in the-X direction is provided at an end portion of the third side wall portion 214 in the-Y direction. A second fixing portion 218 protrudes in the-Y direction from the + Z-direction end of the fourth side wall portion 217. The transformer shield 210 is fixed to the transformer case 200 and the partition member 101 at the second fixing portion 218 (see fig. 4A).

The third sidewall portion 214 has an intermediate portion 219 extending in the + Z direction. The fifth side wall portion 220 protrudes in the-X direction from the end portion of the intermediate portion 219 in the + Y direction. Further, a sixth side wall 221 projects in the-X direction from an end of the intermediate part 219 in the-Y direction.

As shown in fig. 2 and 4A, the partition member 101 is provided with a hole 105 penetrating in the Z direction for inserting the power line 140 (for example, a litz wire) and the signal line 150 therethrough, and the intermediate portion 219, the fifth side wall portion 220, and the sixth side wall portion 221 of the transformer shield 210 are inserted through the hole 105.

The transformer 24b, the transformer case 200, and the transformer shield 210 will be described in detail with reference to fig. 4C, 4D, and 4E. Fig. 4C is a diagram showing a state in which the middle part 219, the fifth side wall part 220, and the sixth side wall part 221 of the transformer shield 210 penetrate the hole 105 of the partition member 101. Fig. 4C is a view of transformer 24b as viewed from the side closer to the-X direction than power line 140 toward the + X direction. Fig. 4D is a cross-sectional view 4D-4D of fig. 4C. Fig. 4E is a cross-sectional view 4E-4E of fig. 4D.

As shown in fig. 4A and 4C, first end of power line 140 is connected to an end of transformer 24b in the-X direction and an end of transformer 24b in the-Z direction, and is inserted through opening 215 to extend in the-X direction and in the + Z direction.

Power line 140 is surrounded by middle portion 219, fifth sidewall portion 220, and sixth sidewall portion 221 of transformer shield 210. Intermediate portion 219, fifth sidewall portion 220, and sixth sidewall portion 221 of transformer shield 210 extend in the + Z direction along power line 140.

Although not shown in fig. 4A and 4C, the signal line 150 electrically connecting the first controller 70 to the switching element 22b and the inverter 24A is inserted through the + Y direction side of the fifth side wall 220 and the-Y direction side of the sixth side wall 221 through the hole 105. That is, in the present embodiment, there are two signal lines 150, one disposed on the + Y direction side of the fifth side wall portion 220 and the other disposed on the-Y direction side of the sixth side wall portion 221, and the through hole 105 is inserted.

In this way, the transformer shield 210 having conductivity (specifically, the fifth side wall portion 220 or the sixth side wall portion 221) is interposed between the power line 140 and the signal line 150, and noise generated by the power line 140 can be appropriately suppressed from interfering with the signal line 150. Therefore, noise interference of the power line 140 with the signal line 150 can be appropriately suppressed without providing a shield (film) for preventing noise from flowing out to the power line 140 itself.

As shown in fig. 4D and 4E, the transformer 24b is disposed inside a space 202 surrounded by the side walls 201 of the transformer case 200. Gaps are provided between the transformer 24b and the side wall 201 of the transformer case 200 and between the transformer 24b and the partition member 101, respectively. The gap is filled with a heat dissipating resin 240 (e.g., a filling resin material).

As shown in fig. 4E, the transformer 24b is formed by coupling an upper core 231 having an E-shaped cross section and a lower core 232 having an E-shaped cross section in a pair, and a coil 233 is wound around each of the middle legs of the upper core 231 and the lower core 232. A bobbin (not shown) made of an insulating material is disposed on the outer periphery of the coil 233.

The gap between the end face of the lower core 232 in the + Z direction and the partition member 101 is filled with the heat dissipating resin 240 as described above. This allows heat generated by coil 233 to be transferred to partition member 101 via lower core 232 and heat-dissipating resin 240. Therefore, the transformer 24b can be appropriately cooled.

The end surface of the upper core 231 in the-Z direction contacts the bottom wall 211 of the transformer shield 210. A first side wall 212 extending in the + Z direction from the end in the + Y direction of the bottom wall 211 of the transformer shield 210 and a second side wall 213 extending in the + Z direction from the end in the-Y direction of the bottom wall 211 are embedded in a heat dissipating resin 240 filled in a gap between the side wall 201 of the transformer case 200 and the transformer 24 b.

Accordingly, the heat generated by the coil 233 can be transmitted to the partition member 101 via the upper core 231, the transformer shield 210 (specifically, the bottom wall 211, the first side wall 212, and the second side wall 213), and the heat dissipating resin 240. Therefore, the transformer 24b can be appropriately cooled.

The transformer shield 210 (specifically, the first side wall 212 and the second side wall 213) is configured not to contact with any of the lower surface (+ Z-direction end surface) of the lower core 232 and the transformer case 200 (the side wall 201). As a result, as shown in fig. 4E, the transformer shield 210 is easily wrapped around the upper core 231 from one side of the upper core 231 in the-Z direction to the + Z direction (from above to below).

As described above, the present embodiment includes: a power line 140 having a first end connected to the transformer 24 b; and a transformer shield 210 having a middle portion 219 extending along power line 140, a fifth side wall portion 220, and a sixth side wall portion 221.

This prevents noise on power line 140 from interfering with other power lines without providing a shield for preventing noise from flowing out on power line 140. Therefore, the size of the power line 140 can be suppressed, and the power supply apparatus 1 can be reduced in size.

In particular, by configuring the transformer shield 210 with a member having good electrical conductivity and good thermal conductivity, the noise shield of the power line 140 and the heat radiation of the transformer 24b can be realized by the transformer shield 210 alone. This can reduce the number of fixing portions (fixing points) compared to the case where the noise shielding member of power line 140 and the heat radiating member of transformer 24b are separately formed.

In the present embodiment, the transformer 24b is accommodated in the first space 102 on the high voltage side, and the secondary side rectifier circuit 24c is accommodated in the second space 103 on the low voltage side. Further, the power line 140 connecting the transformer 24b and the secondary-side rectifying circuit 24c, and the transformer shield 210 are inserted through the hole 105 of the partition member 101. Therefore, the hole 105 can be made small, and the first space and the second space can be appropriately divided.

In the present embodiment, the transformer 24b is housed in a transformer case 200 formed integrally with the base of the high-voltage board 120 and having an open end in the + Z direction, and a heat-dissipating resin 240 is filled in a gap between the transformer 24b and the transformer case 200. That is, the heat dissipating resin 240 is in direct contact with the partition member 101. Therefore, the heat generated by the transformer 24b can be transmitted to the partition member 101 via the heat-dissipating resin 240, and the transformer 24b can be appropriately cooled.

In the present embodiment, the transformer 24b includes an upper core 231, a lower core 232, and a coil 233 surrounded by the upper core 231 and the lower core 232. The + Z side of the lower core 232 is in direct contact with the partition member 101. Therefore, the heat generated by the coil 233 can be transmitted to the partition member 101 via the lower core 232.

Further, the bottom wall 211 of the transformer shield 210 is in direct contact with the-Z side surface of the upper core 231, and the first side wall 212 and the second side wall 213 provided at the end in the + Y direction and the end in the-Y direction of the bottom wall 211 are embedded in the heat dissipating resin 240. Therefore, the heat generated by the coil 233 can be transmitted to the partition member 101 via the upper core 231, the transformer shield 210, and the heat dissipating resin 240. Thus, according to the present embodiment, the transformer 24b can be cooled appropriately.

In the above-described embodiment, the power line 140 and the transformer shield 210 are inserted into the hole 105 of the partition member 101, but the present invention is not limited thereto. By disposing the shield member so as to surround the power line connecting the transformer and the secondary side rectifier circuit, even when the transformer and the secondary side rectifier circuit are accommodated in the same space, it is possible to appropriately prevent noise of the power line connecting the transformer and the secondary side rectifier circuit and interference with other power lines.

Further, since the shield member is disposed so as to surround the surface of the wiring pattern connecting the transformer and the secondary side rectifier circuit, even when the transformer and the secondary side rectifier circuit are mounted on the same substrate and the transformer and the secondary side rectifier circuit are connected by the wiring pattern, it is possible to appropriately prevent noise of the wiring pattern connecting the transformer and the secondary side rectifier circuit from interfering with other power lines.

In the above-described embodiment, the power line connecting the transformer and the secondary side rectifier circuit has been described as an example, but the present invention is not limited to this, and can be applied to a power line electrically connecting elements in the power converter to each other.

(shared structure of smoothing capacitor)

The function of the capacitor 50 will be described with reference to fig. 5A, 5B, and 5C. Fig. 5A, 5B, and 5C are diagrams for explaining a common structure of the capacitors. In fig. 5A, 5B, and 5C, the configuration that is not directly related to the description is omitted.

As described above, in the charger 20, elements other than the secondary-side rectifier circuit 24c are included in the first circuit portion 6 to which a high voltage is applied, and are disposed in the first space 102.

On the other hand, the secondary side rectifying circuit 24c of the charger 20, the capacitor 50, and the power conversion portion 60 are included in the second circuit portion 7 to which the low voltage is applied.

As described above, the insulation level of the first space 102 accommodating the first circuit portion 6 and the insulation level of the second space 103 accommodating the second circuit portion 7 are different from each other. Specifically, the insulation level of the first space 102 is higher than that of the second space 103.

The secondary-side rectifying circuit 24c, the capacitor 50, and the power conversion unit 60 of the charger 20 are mounted on the low-voltage board 130 in the second space 103 and are disposed adjacent to each other.

The capacitor 50 is provided on a power line electrically connecting the secondary-side rectifying circuit 24c of the charger 20 and the battery 3. Capacitor 50 is provided on the input side of power conversion unit 60.

In the power supply device 1, the operation of charging the battery 3 with the electric power from the external power supply 2 and the operation of driving the motor 5 with the electric power of the battery 3 are mutually exclusive operations. In other words, charger 20 and power conversion unit 60 do not operate simultaneously.

Fig. 5B shows an operation state in which the battery 3 is charged with electric power from the external power supply 2. When the battery 3 is charged with the electric power from the external power supply 2, the electric power from the secondary-side rectifying circuit 24c of the charger 20 is smoothed by the capacitor 50 and then output to the battery 3.

Fig. 5C shows an operation state in which the motor 5 is driven by electric power from the battery 3. When the motor 5 is driven by the electric power from the battery 3, the electric power from the battery 3 is smoothed by the capacitor 50 and then input to the electric power conversion unit 60.

As described above, according to the present embodiment, when the battery 3 is charged with the electric power from the external power supply 2, the capacitor 50 can be used as a smoothing capacitor on the output side of the secondary-side rectifying circuit 24c of the charger 20. When the motor 5 is driven by the electric power from the battery 3, the capacitor 50 can be used as a smoothing capacitor on the input side of the power conversion unit 60.

Therefore, the capacitor 50 can be shared by the smoothing capacitor on the output side of the secondary side rectifier circuit 24c of the charger 20 and the smoothing capacitor on the input side of the power conversion unit 60, and the arrangement space of the smoothing capacitors can be reduced.

In addition, according to the present embodiment, the capacitance of the capacitor 50 is smaller than the sum of the capacitance required to smooth the electric power from the secondary side rectifier circuit 24c of the charger 20 and the capacitance required to smooth the electric power to the electric power conversion unit 60.

Specifically, the capacitance of the capacitor 50 may be set to be the larger one of the capacitance necessary for smoothing the power from the secondary side rectifier circuit 24c of the charger 20 and the capacitance necessary for smoothing the power to the power conversion unit 60. With this configuration, the capacitance of the capacitor 50 can be set to the minimum required capacitance.

In addition, the capacitor 50 is provided in the second circuit portion 7 to which a low voltage is applied, and therefore, it is possible to appropriately suppress the withstand voltage from being excessively strong.

In the present embodiment, the secondary-side rectifier circuit 24c of the charger 20, the capacitor 50, and the power conversion unit 60 are all disposed in the second space 103. Therefore, the wiring from the secondary-side rectifier circuit 24c of the charger 20 to the capacitor 50 and the wiring from the capacitor 50 to the power conversion unit 60 can be shortened.

Thus, a capacitor of a relatively small capacity can be used as the capacitor 50, and functions as a smoothing capacitor on the output side of the secondary side rectifier circuit 24c of the charger 20 and a smoothing capacitor on the input side of the power conversion unit 60.

In particular, in the present embodiment, the secondary-side rectifying circuit 24c of the charger 20, the capacitor 50, and the power conversion unit 60 are all mounted on the low-voltage board 130. Thereby, the secondary side rectifier circuit 24c of the charger 20, the capacitor 50, and the power conversion unit 60 can be disposed adjacent to each other. Therefore, the wiring from the secondary-side rectifying circuit 24c of the charger 20 to the capacitor 50 and the wiring from the capacitor 50 to the power conversion unit 60 can be further shortened.

In the above-described embodiment, the case where the capacitor 50 is mounted on the low-voltage substrate 130 is described as an example, but the present invention is not limited thereto. The capacitor 50 may be mounted on a substrate separate from the low voltage substrate 130. The secondary-side rectifier circuit 24c, the capacitor 50, and the power conversion unit 60 of the charger 20 may be mounted on a substrate separate from the low-voltage substrate 130.

(coil of DC/DC converter and its peripheral structure)

The configuration of the coil 42 of the DC/DC converter 40 and its periphery will be described with reference to fig. 6A, 6B, and 6C. Fig. 6A is a perspective view showing the structure of the coil 42 and its periphery. Fig. 6B is a view of the-Z direction as viewed from the + Z direction side of the coil 42. Fig. 6C is a cross-sectional view of 6C-6C of fig. 6B. Fig. 6A to 6C depict the X, Y, and Z axes for ease of understanding. The X, Y, and Z axes are the same as those in fig. 4A to 4E. In fig. 6A to 6C, a configuration not directly related to the description is omitted.

As shown in fig. 6A and 6B, a base 300 of the control board 160 (see fig. 2) is disposed on the + Z side surface of the low-voltage board 130. As described above, the + Z side surface of the low-voltage substrate 130 is covered with the insulating layer of resin.

The housing 310 accommodating the coil 42 is provided integrally with the base 300 so as to protrude from the base 300 in the + Y direction. The base 300 and the housing 310 are both made of resin.

A control board 160 (see fig. 2) is mounted on the base 300, and various semiconductor components constituting the first control unit 70 (see fig. 2) and various semiconductor components constituting the second control unit 80 (see fig. 2) are mounted on the control board 160.

Here, the susceptor 300 and the low voltage substrate 130 are provided with guide holes for positioning. Positioning pins (not shown) are inserted into both the guide holes of the base 300 and the guide holes of the low voltage substrate 130. Thereby, the susceptor 300 is positioned with respect to the low voltage substrate 130.

Further, guide holes for positioning are also provided in the control board 160 and the partition member 101. The partition member 101, the low voltage board 130, the base 300, and the control board 160 are positioned by inserting the positioning pins into the guide holes.

Further, the present invention is not limited to the configuration in which one positioning pin is inserted into all the guide holes of the partition member 101, the low voltage substrate 130, the base 300, and the control substrate 160. For example, the susceptor 300 may be positioned with respect to the control substrate 160 by inserting the first positioning pins into the guide holes of the susceptor 300 and the guide holes of the control substrate 160, and the control substrate 160 may be positioned with respect to the low voltage substrate 130 by inserting the second positioning pins into the guide holes of the control substrate 160 and the guide holes of the low voltage substrate 130. That is, the susceptor 300 may also be positioned with respect to the low voltage substrate 130 by the control substrate 160.

The housing 310 is open at both the-Z direction end and the + Z direction end. The housing 310 has side walls 311 (a first side wall 311a, a second side wall 311b, a third side wall 311c, and a fourth side wall 311 d). A space 312 surrounded by the first side wall 311a, the second side wall 311b, the third side wall 311c, and the fourth side wall 311d is formed.

As shown in fig. 6C, the-Z side surface of the sidewall 311, i.e., the bottom surface 313, is in contact with the low voltage substrate 130. The bottom surface 313 is bonded to the low voltage substrate 130 by an adhesive. On the end portions of the first, second, and third side walls 311a, 311b, 311c in the-Z direction, ribs 314 (first, second, and third ribs 314a, 314b, 314c) protruding toward the space 312 are formed.

The coil 42 is disposed in the space 312 and positioned with respect to the housing 310. More specifically, the four sides of the coil 42 are guided by the first, second, and third ribs 314a, 314b, and 314c, thereby positioning the coil 42 with respect to the housing 310.

According to the above configuration, the coil 42 is positioned with respect to the low voltage substrate 130 by the housing 310, the susceptor 300, and the control substrate 160.

A heat radiation resin 315 is filled in a gap between the coil 42 and the side wall 311 of the case 310. The coil 42 includes: an upper core 42a, a lower core 42b, and a coil body 42c surrounded by the upper core 42a and the lower core 42 b.

the-Z side of the lower core 42b is in direct contact with the low voltage substrate 130. Therefore, the heat generated by the coil main body 42c is transferred to the lower core 42b, and further transferred to the low-voltage substrate 130 in direct contact with the lower core 42 b.

The heat generated by the coil body 42c is transferred to the upper core 42a, and further transferred to the low-voltage substrate 130 via the heat-dissipating resin 315. Therefore, the coil 42 can be appropriately cooled.

As shown in fig. 6A and 6B, power lines 320 and 321 extend in the-Y direction from the-Y-direction end of coil 42. In other words, the first end of power line 320 and the first end of power line 321 are connected to coil 42, respectively. The power lines 320 and 321 are embedded in the heat dissipating resin 315. In addition, instead of embedding both power lines 320 and 321 in heat dissipation resin 315, only one of power lines 320 and 321 may be embedded in heat dissipation resin 315.

As described above, the present embodiment includes: a base 300 fixed to the low voltage substrate 130 and mounted with the control substrate 160; and a housing 310 provided integrally with the base 300 and having a sidewall 311 surrounding the coil 42 and contacting the low voltage substrate 130, the base 300 being positioned with respect to the low voltage substrate 130, and the coil 42 being positioned with respect to the housing 310.

Therefore, the coil 42 can be positioned with respect to the low-voltage substrate 130 without providing a mechanism for positioning the coil 42 and the low-voltage substrate 130.

In the present embodiment, the coil 42 is in direct contact with the low voltage substrate 130. Specifically, the-Z side surface of the lower core 42b of the coil 42 is in direct contact with the insulating layer covering the + Z side surface of the low-voltage substrate 130. This allows heat generated by the coil 42 to be transferred to the low-voltage board 130 while ensuring insulation between the coil 42 and the low-voltage board 130. Therefore, the coil 42 can be appropriately cooled.

In the present embodiment, a heat dissipation resin 315 is filled in a gap between the coil 42 and the side wall 311 of the case 310. Therefore, the heat generated by the coil 42 can be transmitted to the low-voltage substrate 130 via the heat-dissipating resin 315. Therefore, the coil 42 can be appropriately cooled.

In the present embodiment, the susceptor 300 is positioned with respect to the low voltage substrate 130. In particular, when the positioning pins are provided on the base 300, the control board 160 and the low voltage board 130 can be positioned by the base 300. Therefore, the misalignment error between the control board 160 and the low voltage board 130 can be reduced.

In the present embodiment, a rib 314 that protrudes toward the coil 42 and contacts the coil 42 to position the coil 42 is provided on the side wall 311 of the housing 310. Therefore, the coil 42 can be appropriately positioned with respect to the housing 310 with a simple configuration in which the rib 314 is provided on the side wall 311.

In the present embodiment, at least one of the power line 320 and the power line 321 having the first end connected to the coil 42 is embedded in the heat dissipating resin 315. Therefore, the heat dissipation property of the heat generated by at least one of power line 320 and power line 321 can be improved, and at least one of power line 320 and power line 321 can be fixed.

(Current sensor and its peripheral structure)

The current sensor 90 and the configuration of the periphery thereof will be described with reference to fig. 7A, 7B, 7C, and 7D. Fig. 7A to 7D depict the X, Y, and Z axes for ease of understanding. The X, Y and Z axes are the same as those described above. Note that fig. 7A to 7D do not show a configuration that is not directly related to the description.

Fig. 7A is a perspective view showing the current sensor 90 and the configuration of the periphery thereof. Fig. 7B is a plan view showing the structure of the current sensor 90 and its periphery. As shown in fig. 7A, the second cover member 101b is fixed to the + Z side surface of the partition member 101. The second cover member 101b has a plurality of fixing portions 402 used for fixing to the motor 5 (see fig. 2).

As described above, the second circuit portion 7 (see fig. 2) of low voltage is accommodated in the second space 103 (see fig. 2) surrounded by the partition member 101 and the second cover member 101 b.

The second cover member 101b has a wall portion 400 extending in the XY plane. The wall 400 is provided with an opening 401 that communicates the second space 103 with the external space. Wall portion 410 protrudes from wall portion 400 in the + Z direction. That is, wall portion 410 protrudes from wall portion 400 to the external space.

The wall portion 410 includes: a first wall portion 411 extending in the X direction, a second wall portion 412 extending from an end of the first wall portion 411 in the + X direction to the + Y direction, a third wall portion 413 extending from an end of the first wall portion 411 in the-X direction to the + Y direction, and a fourth wall portion 414 connecting an end of the second wall portion 412 in the + Y direction and an end of the third wall portion 413 in the + Y direction.

In a third space 415 surrounded by the wall portion 410 (the first wall portion 411, the second wall portion 412, the third wall portion 413, and the fourth wall portion 414), a wall portion 420 extending in the XY plane is provided. Wall portion 420 is formed integrally with wall portion 400 and wall portion 410. Wall portion 420 may be a separate member from wall portions 400 and 410, and may be fixed to second cover member 101 b.

The current sensor 90 is fixed to the + Z side of the wall portion 420. As described above, the current sensor 90 is a sensor that detects the current value of the electric power output from the power conversion portion 60 and supplied to the motor 5.

The current sensor 90 will be described in detail with reference to fig. 7C. Fig. 7C is a cross-sectional view of 7C-7C of fig. 7B. The current sensor 90 includes a main body 91, a fixing portion 92, and a first hole 93, a second hole 94, and a third hole 95 that penetrate the main body 91 in the Z direction. The first hole 93, the second hole 94, and the third hole 95 are arranged side by side in the X direction.

As described above, the power conversion unit 60 for supplying power to the motor 5 is mounted on the low-voltage board 130. The three-phase ac current output from power conversion unit 60 is output from bus bar 430a, bus bar 430b, and bus bar 430c protruding in the + Z direction from the + Z side surface of low-voltage board 130.

As shown in fig. 7C, the motor 5 is mounted in close contact with the + Z side surface of the wall portion 410 and fixed to the second cover member 101 b. An O-ring is disposed on the + Z side surface of wall 410, and third space 415 surrounded by wall 410 is sealed.

The bus bar 5a, the bus bar 5b, and the bus bar 5c protrude from the motor 5. The bus bar 5a is inserted into the first hole 93. The bus bar 5b is inserted into the second hole 94. The bus bar 5c is inserted into the third hole 95. The bus bar 5a is fixed to the bus bar 430 a. The bus bar 5b is fixed to the bus bar 430 b. The bus bar 5c is fixed to the bus bar 430 c.

Since current sensor 90 is fixed to the + Z side surface of wall portion 420, the distance between current sensor 90 and low-voltage board 130 can be secured. This can suitably prevent noise generated in the circuit mounted on the low-voltage substrate 130 from affecting the current sensor 90. Therefore, the accuracy of the current sensor 90 can be improved.

The wiring process will be described with reference to fig. 7D. Fig. 7D is a cross-sectional view of fig. 7B taken along line 7D-7D. As shown in fig. 7D, a signal line 5D for electrically connecting the power supply device 1 and the motor 5 is provided. A first end of the signal line 5d is connected to the motor 5, and a second end of the signal line 5d is connected to the power supply device 1.

When the power supply device 1 and the motor 5 are fixed to one body, the power supply device 1 and the motor 5 are fixed in a state where the first end of the signal line 5d is connected to the motor 5 and the second end of the signal line 5d is connected to the power supply device 1. Therefore, a relatively long wiring is used as the signal line 5 d.

In the present embodiment, as shown in fig. 7D, in a state where the motor 5 is fixed to the power supply device 1, the signal line 5D for controlling the motor 5 is placed on the + Z side surface of the wall portion 420. Therefore, the signal line 5d can be prevented from entering the second space 103 and coming into contact with other electrical components disposed in the second space 103.

As described above, in the present embodiment, the second cover member 101b includes: a wall portion 400 provided with an opening 401 that communicates the second space 103 with an external space; and a wall portion 410 protruding from the wall portion 400 to the external space and surrounding the opening 401. Further, current sensor 90 for detecting the current value of the electric power output from power conversion unit 60 is disposed in third space 415 surrounded by wall 410.

This ensures the distance between the current sensor 90 and the low-voltage substrate 130. Therefore, it is possible to suitably prevent noise generated in the circuit mounted on the low-voltage substrate 130 from affecting the current sensor 90. Therefore, the accuracy of the current sensor 90 can be improved.

In the present embodiment, a wall portion 420 that protrudes from the wall portion 410 toward the third space 415 and extends on the XY plane is provided, and the current sensor 90 is fixed to the wall portion 420. Therefore, the current sensor 90 can be prevented from moving.

In the present embodiment, the current sensor 90 is disposed on the + Z side surface of the wall portion 420, i.e., on the external space side. Therefore, current sensor 90 can be fixed to wall portion 420 from the external space side.

In the present embodiment, wall portion 420 is a part of second cover member 101b, and is formed integrally with at least one of wall portion 400 and wall portion 410. Therefore, the wall portion 420 can be prevented from falling off.

In the present embodiment, the signal line 5d is placed on the wall portion 420. Therefore, the signal line 5d can be prevented from entering the second space 103 and coming into contact with other electrical components disposed in the second space 103.

The embodiments of the present invention have been described above, but the present invention is not limited to the above-described embodiments, and can be implemented by appropriately modifying the embodiments without departing from the scope of the present invention. The above-described embodiments and modifications can be used in appropriate combinations.

Industrial applicability

The utility model discloses a power conversion device can realize miniaturizing, suitably uses in electric automobile (EV).

Claims (6)

1. A power conversion device is characterized by comprising:

a reactor;

a power line connected to the reactor; and

and a shield member having a contact portion that contacts the reactor and a shield portion that extends along the power line and shields electric waves emitted from the power line.

2. The power conversion apparatus according to claim 1,

further comprises a housing divided into a first space and a second space by a partition member,

the reactor is accommodated in the first space,

the power line and the shield member are provided on the partition member, and are inserted into a hole that communicates the first space with the second space.

3. The power conversion apparatus according to claim 2,

a signal wire is inserted through the hole,

the shield member is interposed between the power line and the signal line.

4. The power conversion apparatus according to any one of claims 1 to 3,

the reactor is housed in a case,

a gap between the reactor and the case is filled with a heat-dissipating resin,

the shield member is in contact with the heat dissipating resin.

5. The power conversion apparatus according to claim 4,

the reactor includes an upper first core and a lower second core,

the shield member is in contact with the upper first core and in contact with the heat dissipating resin.

6. The power conversion apparatus according to claim 5,

the shield member does not contact any one of the lower surface of the lower second core and the outer shell.

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