JP7294247B2 - electric unit - Google Patents

Description

The disclosure provided herein relates to an electrical unit having electrical components.

2. Description of the Related Art As disclosed in Patent Literature 1, a power conversion device is known in which a group of electronic components and a busbar are housed in a case.

JP 2011-167056 A

In the power converter disclosed in Patent Literature 1, a high-voltage cable is connected to the bus bar. Joule heat is generated at the connection portion of the high-voltage cable with the bus bar. Due to the heat transfer and heat radiation of this Joule heat, there is a risk that the temperature of the electronic component group (electric component) will rise.

An object of the present disclosure is to provide an electric unit in which temperature rise of electric components is suppressed.

An electrical unit according to one aspect of the present disclosure includes an electrical component (410);
A plurality of conductive portions (421 to 423) having one end (420a) connected to an electric component and the other end (420b) connected to an external terminal (501 to 503), and covering the central portion of each of the plurality of conductive portions a resin module (420) comprising an insulating resin portion (650) that
Cases (671, 672) having storage spaces for storing the electrical components and the resin module, respectively, and at least a part of the storage spaces are divided into a first region where the electrical components and one end of the conductive part are provided and the other end of the conductive part. and a case (670) provided with a dividing wall (677) that divides with the resin portion.

According to this, the connecting portions of the external terminals (501-503) to the other ends (420b) of the conductive portions (421-423) are located in the second region. A resin portion (650) and a dividing wall (677) are located between the second region and the first region where the electrical component (410) is provided. Therefore, the resin portion (650) and the dividing wall (677) suppress the heat transfer to the electric component (410) of the heat generated at the external terminal due to energization or the like. This suppresses the temperature rise of the electrical component (410).

It should be noted that the reference numbers in parentheses above merely indicate the correspondence with the configurations described in the embodiments described later, and do not limit the technical scope in any way.

1 is a circuit diagram showing an in-vehicle system; FIG. It is a schematic diagram for demonstrating an electromechanical integrated unit. It is a bottom view of a power converter device. It is a partial expansion perspective view of a power converter device. 4 is a cross-sectional view taken along line VV shown in FIG. 3; FIG. It is sectional drawing which shows the attachment state of a phase stator busbar. FIG. 4 is a cross-sectional view taken along line VII-VII shown in FIG. 3;

A plurality of modes for carrying out the present disclosure will be described below with reference to the drawings. In each form, the same reference numerals may be given to the parts corresponding to the matters described in the preceding form, and overlapping explanations may be omitted. When only a part of the configuration is described in each form, the previously described other forms can be applied to other parts of the configuration.

It is possible to combine the parts that are specifically stated to be combinable in each embodiment. In addition, if there is no particular problem with the combination, it is possible to partially combine the embodiments, the embodiments and the modified examples, and the modified examples even if it is not explicitly stated that the combination is possible. be.

(First embodiment)
<In-vehicle system>
First, based on FIG. 1, the vehicle-mounted system 100 to which the power converter 400 is applied will be described. This in-vehicle system 100 constitutes a system for an electric vehicle. The in-vehicle system 100 has a battery 200 and an electromechanical integrated unit 300 . The electromechanical integrated unit 300 has a power conversion device 400 and a motor 500 .

In-vehicle system 100 also includes a plurality of ECUs (not shown). These multiple ECUs transmit and receive signals to and from each other via bus wiring. A plurality of ECUs cooperate to control the electric vehicle. Power running and regeneration of motor 500 according to the SOC of battery 200 are controlled by a plurality of ECUs. SOC is an abbreviation for state of charge. ECU is an abbreviation for electronic control unit.

The ECU has at least one arithmetic processing unit (CPU) and at least one memory device (MMR) as a storage medium for storing programs and data. The ECU is provided by a microcomputer having a computer readable storage medium. The storage medium is a non-transitional tangible storage medium that non-temporarily stores a computer-readable program. A storage medium may be provided by a semiconductor memory, a magnetic disk, or the like. The constituent elements of the in-vehicle system 100 are individually outlined below.

Battery 200 has a plurality of secondary batteries. These secondary batteries constitute a battery stack connected in series. The SOC of this battery stack corresponds to the SOC of battery 200 . A lithium-ion secondary battery, a nickel-hydrogen secondary battery, an organic radical battery, or the like can be used as the secondary battery.

The power conversion device 400 performs power conversion between the battery 200 and the motor 500 . The power conversion device 400 converts the DC power of the battery 200 into AC power. The power conversion device 400 converts AC power generated by power generation (regeneration) of the motor 500 into DC power. The power conversion device 400 corresponds to the electric unit.

A motor 500 is connected to an axle of an electric vehicle (not shown). Rotational energy (power) of the motor 500 is transmitted to the running wheels of the electric vehicle via the axle. Conversely, the rotational energy of the running wheels is transmitted to the motor 500 via the axle.

The motor 500 is driven by AC power supplied from the power converter 400 . This imparts a propulsive force to the running wheels. Also, the motor 500 is regenerated by rotational energy transmitted from the running wheels. The AC power generated by this regeneration is converted into DC power by the power conversion device 400 . This DC power is supplied to battery 200 . The DC power is also supplied to various electrical loads mounted on the electric vehicle.

<Power converter>
Next, the power conversion device 400 will be described. A power conversion device 400 includes an inverter 410 and a resin module 420 . Inverter 410 converts the DC power of battery 200 into AC power. This AC power is supplied to the motor 500 . Inverter 410 converts AC power generated by motor 500 into DC power. This DC power is supplied to battery 200 . Resin module 420 connects inverter 410 and motor 500 . Note that the power conversion device 400 may include a converter that steps up or steps down the input voltage.

As shown in FIG. 1, power conversion device 400 includes N bus bar 401 and P bus bar 402 . A battery 200 is connected to these N busbar 401 and P busbar 402 . N busbar 401 is connected to the negative electrode of battery 200 . P bus bar 402 is connected to the positive electrode of battery 200 .

Resin module 420 includes U-phase busbar 421 , V-phase busbar 422 , and W-phase busbar 423 . Inverter 410 and motor 500 are electrically connected via U-phase bus bar 421 , V-phase bus bar 422 , and W-phase bus bar 423 . These phase busbars correspond to conductive portions. In FIG. 1, white circles indicate connection portions of various busbars. These connecting portions are electrically connected by, for example, bolts or welding.

<Inverter>
Inverter 410 has smoothing capacitor 430 and switch group 440 . N busbar 401 and P busbar 402 are electrically connected to smoothing capacitor 430 and switch group 440, respectively. Inverter 410 corresponds to an electrical component. The switch group 440 corresponds to electronic elements.

The switch group 440 includes U-phase switch modules 441 to W-phase switch modules 443 . Each of these three-phase switch modules has a high-side switch 451 and a low-side switch 452 . Also, each of the three-phase switch modules has a high-side diode 451a and a low-side diode 452a. These switches and diodes are covered and protected by a sealing resin.

In this embodiment, n-channel IGBTs are used as the high-side switch 451 and the low-side switch 452 . As shown in FIG. 1, the emitter electrode of the high side switch 451 and the collector electrode of the low side switch 452 are connected. Thereby, the high side switch 451 and the low side switch 452 are connected in series.

Also, the collector electrode of the high side switch 451 is connected to the cathode electrode of the high side diode 451a. The emitter electrode of the high side switch 451 is connected to the anode electrode of the high side diode 451a. Thus, the high side diode 451 a is connected in anti-parallel to the high side switch 451 .

Similarly, the collector electrode of the low side switch 452 is connected to the cathode electrode of the low side diode 452a. The emitter electrode of the low side switch 452 is connected to the anode electrode of the low side diode 452a. Thus, the low side diode 452 a is connected in anti-parallel to the low side switch 452 .

As described above, the switch is covered and protected by the sealing resin. The ends of the terminals connected to the collector electrode of the high-side switch 451, the midpoint between the high-side switch 451 and the low-side switch 452, and the emitter electrode of the low-side switch 452 are exposed from this sealing resin. . The tips of the terminals connected to the gate electrodes of the high-side switch 451 and the low-side switch 452 are exposed from the sealing resin. These terminals are hereinafter referred to as collector terminal 450a, midpoint terminal 450c, emitter terminal 450b, and gate terminal 450d.

The collector terminal 450a is connected to the P bus bar 402 as shown in FIG. Emitter terminal 450 b is connected to N bus bar 401 . With such an electrical connection, the high side switch 451 and the low side switch 452 are serially connected in order from the P bus bar 402 toward the N bus bar 401 .

A midpoint terminal 450 c of the U-phase switch module 441 is connected to the U-phase bus bar 421 . A midpoint terminal 450 c of the V-phase switch module 442 is connected to the V-phase bus bar 422 . A midpoint terminal 450 c of the W-phase switch module 443 is connected to the W-phase bus bar 423 .

Motor 500 has a U-phase stator coil, a V-phase stator coil, and a W-phase stator coil. A U-phase stator bus bar 501 is connected to the U-phase stator coil. A V-phase stator bus bar 502 is connected to the V-phase stator coil. A W-phase stator bus bar 503 is connected to the W-phase stator coil. These phase stator busbars correspond to external terminals.

U-phase bus bar 421 is connected to U-phase stator bus bar 501 . A V-phase bus bar 422 is connected to the V-phase stator bus bar 502 . A W-phase bus bar 423 is connected to the W-phase stator bus bar 503 . Thus, inverter 410 and motor 500 are electrically connected.

A gate terminal 450d of each of the high-side switch 451 and the low-side switch 452 included in the U-phase switch module 441 to W-phase switch module 443 is connected to a gate driver.

The gate drivers are contained on circuit board 470 shown in FIG. 1 along with some of the ECUs described above. The ECU generates control signals and outputs them to the gate drivers. The gate driver amplifies the control signal and outputs it to gate terminal 450d. Accordingly, the high side switch 451 and the low side switch 452 are controlled to be opened and closed by the ECU. The board on which the gate driver is mounted and the board on which the ECU is mounted may be separate bodies.

The ECU generates pulse signals as control signals. The ECU adjusts the on-duty ratio and frequency of this pulse signal. The on-duty ratio and frequency are determined based on the outputs of a current sensor 460, which will be described later, a rotation angle sensor (not shown), and the like.

When the motor 500 is powered, each of the high-side switch 451 and the low-side switch 452 provided in the three-phase switch module is PWM-controlled by the output of the control signal from the ECU. Thereby, a three-phase alternating current is generated in the power conversion device 400 . This 3-phase alternating current is input to the 3-phase stator coils via the 3-phase busbars and the 3-phase stator busbars. A three-phase rotating magnetic field is thereby generated by the three-phase stator coils. Rotational torque is generated in the rotor by the interaction of this three-phase rotating magnetic field and the magnetic field generated by the rotor of the motor 500 .

When the motor 500 generates power (regenerates) due to the rotational energy of the running wheels, the ECU stops outputting the control signal, for example. Accordingly, AC power generated by power generation passes through diodes provided in the three-phase switch module. As a result, AC power is converted to DC power.

The types of switch elements provided in each of the U-phase switch module 441 to W-phase switch module 443 are not particularly limited, and MOSFETs, for example, may be employed. Semiconductor elements such as switches and diodes included in these three-phase switch modules can be manufactured from semiconductors such as Si and wide-gap semiconductors such as SiC. The constituent material of the semiconductor element is not particularly limited.

Also, the number of each of the high-side switches 451 and the low-side switches 452 included in the three-phase switch module is not limited to one. At least one of the three-phase switch modules may include a plurality of high side switches 451 connected in parallel and a plurality of low side switches 452 connected in parallel. The number of switches to be connected in parallel can be determined based on the rated current of the switches, the amount of current that can be passed through the power conversion device 400, and the like.

<Current sensor>
The power conversion device 400 has a current sensor 460 provided in the resin module 420 in addition to the constituent elements described so far. The current sensor 460 has a U-phase magnetoelectric converter 461 , a V-phase magnetoelectric converter 462 , and a W-phase magnetoelectric converter 463 . These three magnetoelectric converters are of the magnetic balance type, and detect the current flowing through each of the three phase busbars. These three magnetoelectric conversion units correspond to the sensor unit.

The current sensor 460 has a wiring board 464 and signal terminals 465 in addition to the components described above. Three magnetoelectric conversion units are mounted on the wiring board 464 . The signal terminal 465 has the function of electrically connecting the magnetoelectric conversion section provided on the wiring board 464 and the circuit board 470 . The signal terminal 465 corresponds to the output terminal.

<Mechanical Configuration of Power Converter>
Next, the mechanical configuration of power converter 400 will be described. Accordingly, the three directions that are orthogonal to each other are hereinafter referred to as the x-direction, the y-direction, and the z-direction. In the drawings, description of "direction" is omitted, and simply x, y, and z are illustrated. The x direction corresponds to the horizontal direction. The y direction corresponds to the vertical direction. The z direction corresponds to the standing direction.

The power converter 400 has a capacitor case 610, a cooler 630, a terminal block 650, and an inverter housing 670 shown in FIGS.

Note that FIG. 2 shows the power conversion device 400 in a partial cross-sectional view. FIG. 3 schematically shows capacitor case 610 in comparison with cooler 630 , terminal block 650 , and inverter housing 670 .

Capacitor case 610 is made of an insulating resin material. A smoothing capacitor 430 is accommodated in the capacitor case 610 . A part of each of the N bus bar 401 and the P bus bar 402 is housed in the capacitor case 610 .

Cooler 630 accommodates U-phase switch module 441 to W-phase switch module 443 . Cooler 630 functions to cool these three-phase switch modules.

The terminal block 650 is made of an insulating resin material. Center portions of the three phase bus bars and the plurality of signal terminals 465 are insert-molded in the terminal block 650 . A terminal block 650 is provided with a wiring board 464 on which three magnetoelectric conversion units are mounted. The three phase busbars and the three magnetoelectric converters are arranged facing each other in the z direction. The resin module 420 includes a terminal block 650 and three phase busbars. The terminal block 650 corresponds to the resin portion.

Inverter housing 670 is made of a high magnetic permeability material having a magnetic permeability higher than that of air. Specifically, inverter housing 670 is made of a metallic material such as alumina.

The inverter housing 670 has a box shape with an opening. Inverter housing 670 accommodates capacitor case 610 , cooler 630 , and terminal block 650 . A cooler 630 is positioned between the capacitor case 610 and the terminal block 650 in the x-direction.

Capacitor case 610 and terminal block 650 are bolted to inverter housing 670 . Cooler 630 is pressed against inverter housing 670 by a spring body (not shown). Because of this mechanical coupling arrangement, the inverter housing 670 and the various electrical devices contained therein are actively heat conductive.

<Mechanical and electrical integrated unit>
As shown in FIG. 2, inverter housing 670 is connected to motor housing 510 that houses motor 500 . Thus, the electromechanical integrated unit 300 is configured. Motor housing 510 may house a transmission together with motor 500 .

Inverter housing 670 and motor housing 510 are aligned in the z-direction. Inverter housing 670 is provided closer to the top plate of the electric vehicle than motor housing 510 is. Therefore, when the electric vehicle is on a horizontal plane, inverter housing 670 is provided above motor housing 510 in the vertical direction.

<Cooler>
As shown in FIGS. 3 and 4, the cooler 630 has a delivery pipe 631, an exhaust pipe 632, and a plurality of relay pipes 633. As shown in FIG. The distribution pipe 631 and the discharge pipe 632 are connected via a plurality of relay pipes 633 . Refrigerant is supplied to the distribution pipe 631 . This refrigerant flows from the distribution pipe 631 to the discharge pipe 632 via a plurality of relay pipes 633 .

The delivery pipe 631 and the discharge pipe 632 each extend in the y-direction. The delivery pipe 631 and the discharge pipe 632 are spaced apart in the x-direction. Each of the multiple relay pipes 633 extends along the x-direction from the distribution pipe 631 toward the discharge pipe 632 . The supply port of the distribution pipe 631 to which the coolant is supplied from the outside and the discharge port of the discharge pipe 632 that discharges the coolant supplied from the relay pipe 633 to the outside are spaced apart in the x-direction.

A plurality of relay pipes 633 are spaced apart in the y direction and arranged side by side. A gap is formed between two adjacent relay pipes 633 . A U-phase switch module 441 to a W-phase switch module 443 are individually provided in each of the plurality of gaps. This constitutes a power module.

The main surface of each of these three-phase switch modules is in contact with the relay pipe 633 . A plurality of relay pipes 633 are compressed in the y-direction by an urging force applied from a spring body (not shown). This narrows the width of the gap in the y direction.

By narrowing the width of the air gap in the y direction, the contact area between each of the three-phase switch modules and the relay pipe 633 is increased. The heat generated in each of the three-phase switch modules is actively radiated to the coolant through the relay pipe 633 .

Cooler 630 is pressed against inverter housing 670 by the biasing force of the spring body. As a result, cooler 630 and inverter housing 670 can positively conduct heat.

<Terminal block>
As shown in FIG. 4, the terminal block 650 has a base portion 651 , a flange portion 652 , a connector portion 653 and a lid portion 654 . The base portion 651, the flange portion 652, and the connector portion 653 are integrally connected by a resin material. The lid portion 654 is bolted to the base portion 651 .

The base 651 has a substantially rectangular parallelepiped shape with the y direction as the longitudinal direction. Therefore, the base 651 has a first side surface 651a and a second side surface 651b aligned in the x direction, a first end surface and a second end surface aligned in the y direction, and an upper surface and a lower surface aligned in the z direction.

As shown in FIGS. 3 and 4, the flange portion 652 is integrally connected to each of the first end face and the second end face of the base portion 651 . These two flange portions 652 are insert-molded with metal collars. The collar has an annular shape that is open in the z-direction. The shaft of the bolt is passed through the hollow of this collar. The tip of this shaft portion is fastened to the inverter housing 670 . The terminal block 650 is thereby fixed to the inverter housing 670 .

A connector portion 653 is integrally connected to the upper surface of the base portion 651 . The connector portion 653 extends in the z-direction away from the top surface.

A plurality of signal terminals 465 are insert-molded in the connector portion 653 and the base portion 651 . Signal terminal 465 extends in the z-direction. One end of the signal terminal 465 is exposed from the tip surface of the connector portion 653 . One end of this signal terminal 465 is soldered to the circuit board 470 . The other end of the signal terminal 465 is exposed from the bottom surface of the base portion 651 . The other end of this signal terminal 465 is soldered to the wiring board 464 .

Central portions of the U-phase bus bar 421 to W-phase bus bar 423 are insert-molded into the base portion 651 . These three phase busbars are made of a metallic material such as copper or aluminum having higher rigidity than the terminal block 650 . These three phase bus bars are manufactured by pressing a flat metal plate. One ends 420a of these three phase bus bars protrude from the first side surface 651a. These three ends 420a are spaced apart in the y direction.

Central portions of the three phase busbars insert-molded in the base portion 651 extend in the y direction. The other ends 420b of these three phase busbars protrude from the second side surface 651b. These three other ends 420b are spaced apart in the y direction.

Each of these three other ends 420b extends in the x-direction away from the second side surface 651b, then bends and extends from the lower surface toward the upper surface in the z-direction. A bolt hole 420c is formed in each of these three other ends 420b extending in the z-direction. The diameter of the bolt hole 420c is longer than the distance between the three other ends 420b.

A wiring substrate 464 is provided on the lower surface of the base portion 651 . The wiring board 464 is fixed to the base portion 651 by thermal caulking or the like. The central portions of the three phase bus bars are located in the z-direction projected regions of the three magnetoelectric conversion portions mounted on the wiring board 464 . As a result, the magnetic field components generated from the currents flowing through the three phase busbars respectively pass through the three magnetoelectric converters. The lid portion 654 is bolted to the lower surface side of the base portion 651 so as to cover the wiring board 464 . Note that the lid portion 654 may be omitted.

In the following description, the back side of the surface of the lid portion 654 that faces the base portion 651 is referred to as a lower surface 650d for simplicity of notation. An upper surface of the base 651 is given a reference numeral and indicated as an upper surface 650c.

<Inverter housing>
Inverter housing 670 is made of a high magnetic permeability material having a magnetic permeability higher than that of air. Specifically, inverter housing 670 is made of a metallic material such as alumina or iron.

Inverter housing 670 has a top wall 671 and side walls 672 . The top wall 671 and side walls 672 are included in the housing.

The top wall 671 has an inner top surface 671a and an outer top surface 671b aligned in the z direction. The top wall 671 has a flat plate shape with a thin thickness in the z direction.

The side wall 672 extends annularly in the circumferential direction around the z-direction along the edge of the inner top surface 671a. A storage space is formed by the inner surface 672a of the side wall 672 and the inner top surface 671a surrounded by it. A capacitor case 610, a cooler 630, and a terminal block 650 are housed in this housing space.

Specifically, sidewall 672 includes a first wall 673 and a second wall 674 spaced apart in the x-direction and a third wall 675 and a fourth wall 676 spaced apart in the y-direction. The first wall 673, the third wall 675, the second wall 674, and the fourth wall 676 are arranged in order in the circumferential direction and connected. As a result, the side wall 672 forms an annular shape in the circumferential direction.

The opening of the storage space is defined on the tip side of the four walls provided by these side walls 672 . This opening is closed by the motor housing 510 when the inverter housing 670 is assembled to the motor housing 510 .

As shown in FIG. 2, the circuit board 470 is provided outside the storage space. The circuit board 470 is provided on the outer top surface 671b side of the inverter housing 670 .

For example, as shown in FIG. 4, the top wall 671 is formed with a plurality of through holes 671c opening to an inner top surface 671a and an outer top surface 671b. Through the through hole 671c, the gate terminal 450d of the switch module housed in the cooler 630 and the signal terminal 465 of the resin module 420 extend upward from the storage space toward the outer top surface 671b side. The leading end sides of the gate terminal 450d and the signal terminal 465 are inserted into through holes of the circuit board 470 and soldered to the circuit board 470 . A cover for protecting the circuit board 470 may be provided on the outer top surface 671 b side of the top wall 671 .

As described above, the ends of the collector terminal 450a, the emitter terminal 450b, the midpoint terminal 450c, and the gate terminal 450d are exposed from the sealing resin of the switch module housed in the cooler 630. FIG. Each of these four terminals extends in the z-direction. However, the collector terminal 450a, the emitter terminal 450b, and the middle point terminal 450c extend in opposite directions to the gate terminal 450d. Collector terminal 450 a , emitter terminal 450 b , and midpoint terminal 450 c each extend toward the open side of inverter housing 670 . On the other hand, the gate terminal 450d extends toward the through hole 671c of the ceiling wall 671 as described above.

As shown in FIG. 3, the capacitor case 610, the cooler 630, and the terminal block 650 are located between the first wall 673 and the second wall 674 spaced apart in the x direction. The capacitor case 610 is located on the first wall 673 side, and the terminal block 650 is located on the second wall 674 side. Cooler 630 is located between capacitor case 610 and terminal block 650 .

Although not shown, P bus bar 402 and N bus bar 401 extend from condenser case 610 toward cooler 630 . The collector terminal 450a of the switch module housed in the cooler 630 and the P bus bar 402 are laser welded. Emitter terminal 450b and N bus bar 401 are laser welded.

4, one end 420a of each of the three phase busbars extends from the terminal block 650 toward the cooler 630. As shown in FIG. These three one ends 420a and the midpoint terminals 450c of each of the three switch modules are individually laser welded. A power conversion circuit is configured by the laser welding described above.

The other ends 420b of the three phase busbars protrude from the second side surface 651b of the terminal block 650, then bend and extend toward the ceiling wall 671 in the z direction. As shown in FIG. 5, the portions of the three other ends 420b extending in the z-direction are spaced apart in the y-direction.

<Partition wall>
As shown in FIGS. 5 and 7, inverter housing 670 has partition walls 677 for roughly dividing the storage space into a plurality of spaces. The partition wall 677 stands up from the inner ceiling surface 671a of the ceiling wall 671 in the z direction. The partition wall 677 is connected to two different points on the inner surface 672a of the side wall 672 extending in the circumferential direction around the z direction. Specifically, the partition wall 677 is connected to the inner side surfaces 672a of the second wall 674 and the fourth wall 676 extending in different directions. Thus, the storage space surrounded by the side wall 672 is partitioned into two by the partition wall 677 . A partition wall 677 corresponds to the dividing wall.

If the space divided into these two is defined as a large space and a small space according to its size, the capacitor case 610, the cooler 630, and the phase bus bar protruding from the first side surface 651a of the terminal block 650 are located in the large space. One end 420a is located. The terminal block 650 is positioned between the large space and the small space, and is aligned with the partition wall 677 in the z direction. The other end 420b of the phase busbar projecting from the second side surface 651b of the terminal block 650 is located in the small space. The large space corresponds to the first area. The small space corresponds to the second area.

The partition wall 677 has a first opposing surface 677a that partitions a portion of the large space and a second opposing surface 677b that partitions a portion of the small space. The first opposing surface 677a faces the inner side surfaces 672a of the first wall 673 and the third wall 675 while being separated from each other. The second facing surface 677b faces the inner side surfaces 672a of the second wall 674 and the fourth wall 676 while being separated from each other.

As shown schematically by dashed lines in FIG. 3, the partition 677 extends from the second wall 674 in the x-direction and then toward the fourth wall 676 in the y-direction. In the following description, a portion of the partition wall 677 extending in the x-direction is referred to as a first partition wall 678 and a portion thereof extending in the y-direction is referred to as a second partition wall 679 for simplicity of explanation.

The tip side of the first partition 678 is positioned closer to the opening side of the inverter housing 670 in the z direction than the tip side of the second partition 679 . When the inverter housing 670 is assembled to the motor housing 510, the distance between the tip side of the first partition wall 678 and the outer wall surface 510a of the motor housing 510 becomes substantially zero. However, the distance between the tip side of the second partition wall 679 and the outer wall surface 510a of the motor housing 510 does not become substantially zero. A gap is created between the two. A terminal block 650 is provided in this gap.

As shown in FIG. 7, the separation distance between the tip side of the second partition wall 679 and the upper surface 650c of the terminal block 650 is almost zero. When the inverter housing 670 is assembled to the motor housing 510, the separation distance between the bottom surface 650d of the terminal block 650 and the outer wall surface 510a of the motor housing 510 becomes almost zero.

Due to the configuration described above, the large space and the small space are separated by the partition wall 677 and the terminal block 650 . 2 and 7, the boundary line BL separating the large space and the small space is indicated by a dashed line.

As shown in FIG. 7, although the terminal block 650 is located on the boundary line BL, most of it is located in a large space. The distance in the x direction between the second side surface 651b of the terminal block 650 and the second opposing surface 677b of the second partition wall 679 is shorter than the distance in the x direction between the first side surface 651a and the first opposing surface 677a. there is

The wiring board 464 provided on the terminal block 650 is located in a large space. Therefore, the U-phase magnetoelectric converter 461 to the W-phase magnetoelectric converter 463 mounted on the wiring board 464 are also located in a large space.

A plurality of signal terminals 465 are insert-molded in the connector portion 653 and the base portion 651 of the terminal block 650 as described above. The connector portion 653 and the signal terminal 465 are also located in a large space.

As shown in FIG. 4, the connector portion 653 and the signal terminals 465 are aligned with the second partition wall 679 in the y direction. The connector portion 653 and the signal terminal 465 are aligned in the y-direction with the other end 420b side of the phase bus bar via the second partition wall 679 .

<small space>
As shown in FIGS. 5 and 7, the general shape of the small space is defined by the surfaces shown below. The shape of the small space in the x direction is defined by the second facing surface 677b of the second partition wall 679, the second side surface 651b of the terminal block 650, and the inner side surface 672a of the second wall 674 aligned in the x direction. The y-direction shape of the small space is formed by the second opposing surface 677b of the first partition wall 678 and the inner side surface 672a of the fourth wall 676 aligned in the y-direction. The shape of the small space in the z-direction is formed by the regions between the above-mentioned surfaces arranged in the x-direction and the y-direction on the inner top surface 671a.

<Partition wall>
As shown in FIGS. 3 and 5, the inverter housing 670 of this embodiment has a partition wall 680 rising from the inner top surface 671a of the top wall 671 in the z direction. A partition wall 680 extends in the x-direction from the second wall 674 toward the second partition wall 679 .

The partition wall 680 is located between the fourth wall 676 and the first partition wall 678 within the small space. The inner side surface 672a of the fourth wall 676 faces the first partition surface 680a of the partition wall 680 in the y direction. The second facing surface 677b of the first partition wall 678 faces the second partition surface 680b of the partition wall 680 in the y direction.

The other ends 420b of the U-phase busbars 421 to W-phase busbars 423 are arranged in the y direction between the second facing surface 677b of the first partition wall 678 and the second partition surface 680b of the partition wall 680. As shown in FIG. A gap is formed between these three other ends 420b, between the other ends 420b and the second opposing surface 677b, and between the other ends 420b and the second partition surface 680b. A gap is formed between the other end 420b and the inner top surface 671a. The diameter of the bolt hole 420c formed in the other end 420b is longer than each of these gaps.

The bolt holes 420c formed in each of the three other ends 420b and the second partition wall 679 are arranged to face each other in the x direction. Nuts 681 are provided at positions aligned with the three bolt holes 420c in the second partition 679 in the x direction.

The nut 681 has a screw hole opening in the x direction, and a screw groove is formed on the wall surface of this screw hole. The screw holes of the three nuts 681 and the three bolt holes 420c are individually arranged in the x direction.

When inverter housing 670 is assembled to motor housing 510, the distal ends of U-phase stator bus bar 501 to W-phase stator bus bar 503 are inserted into small spaces as shown in FIGS. In the small space, the stator bus bar, phase bus bar, and nut 681 are arranged in order in the x direction.

A fixing hole 500c is formed through each of the three stator bus bars in the x direction. The fixing holes 500c of these three stator busbars, the bolt holes 420c of the three phase busbars, and the screw holes of the three nuts 681 are arranged in order in the x direction.

A shaft portion of one bolt 520 is passed through these three holes arranged in the x direction. The tip side of the shaft portion of the bolt 520 is fastened to the screw groove of the screw hole. As a result, the other end 420 b of the phase bus bar and the tip side of the stator bus bar are clamped between the head of the bolt 520 and the nut 681 . As a result, the phase bus bar and the stator bus bar are mechanically and electrically connected.

Although not shown, a window for inserting the bolt 520 into the small space is formed in a portion of the second wall 674 that forms the small space. The length in the x direction between the window opening region on the inner side surface 672a of the second wall 674 and the stator bus bar is shorter than the length of the bolt 520 in the x direction.

<Effect>
As described above, the storage space of the inverter housing 670 is divided into a large space and a small space by the partition wall 677 and the terminal block 650 . One end 420a side of each of U-phase bus bar 421 to W-phase bus bar 423 exposed from capacitor case 610, cooler 630, and terminal block 650 is provided in a large space. The other end 420b side of each of the U-phase busbar 421 to the W-phase busbar 423 is provided in a small space. The tip side of each of U-phase stator bus bar 501 to W-phase stator bus bar 503 is bolted to the other end side.

Due to such a configuration, the heat generated in the phase stator bus bar by energization or the like in the small space is suppressed from being transferred to the large space in which the capacitor case 610 and the cooler 630 are accommodated by heat transfer or heat radiation. . As a result, the temperature rise of the smoothing capacitor 430 housed in the capacitor case 610 and the switch group 440 housed in the cooler 630 is suppressed. Temperature rise of inverter 410 is suppressed.

As described above, the cooler 630 is housed in the large space. Therefore, even if the heat generated by the phase stator bus bar is transferred from the small space to the large space via the partition wall 677 and the terminal block 650, the temperature rise of the switch group 440 due to the heat is suppressed. Temperature rise of semiconductor elements such as switches and diodes included in the three-phase switch modules included in the switch group 440 is suppressed.

Also, the condenser case 610 is further away from the small space than the cooler 630 is. A cooler 630 is positioned between the condenser case 610 and the small space. Therefore, even if the heat generated in the phase stator bus bar is transferred from the small space to the large space through the partition wall 677 and the terminal block 650, the heat may raise the temperature of the smoothing capacitor 430 housed in the capacitor case 610. Suppressed.

A terminal block 650 is provided with a U-phase magnetoelectric conversion section 461 to a W-phase magnetoelectric conversion section 463 . The terminal block 650 is arranged close to the partition wall 677 in the z-direction so that the distance therebetween is almost zero. A partition wall 677 rises from the top wall 671 of the inverter housing 670 to allow positive heat conduction between the inverter housing 670 and the cooler 630 .

According to this, the temperature rise of the inverter housing 670 due to the heat generated by the phase stator bus bar is suppressed. Temperature rise of the partition wall 677 is suppressed. Temperature rise of the terminal block 650 arranged close to the partition wall 677 is suppressed. Then, the temperature rise of the three magnetoelectric conversion units provided on this terminal block 650 is suppressed. This suppresses a decrease in current detection accuracy.

The heat generated by the phase stator bus bar provided in the small space is transferred to each part forming the small space, and then transferred to each part forming the large space. This heat diffuses while being transmitted from the small space side to the large space side.

In this embodiment, most of the terminal block 650 is provided in a large space. The three magnetoelectric conversion units provided on the terminal block 650 are also provided in a large space. Therefore, the temperature rise of the magnetoelectric conversion part due to heat transfer from the phase stator bus bar is suppressed.

A second partition 679 is located between the signal terminal 465 and the other end 420b of the phase bus bar. According to this, the heat generated in the phase stator bus bar is suppressed from being transferred to the signal terminal 465 by heat transfer, heat radiation, or the like.

Between the other ends 420b of each of the U-phase busbars 421 to the W-phase busbars 423 aligned in the y direction in the small space, between the other ends 420b and the second facing surface 677b, and between the other ends 420b and the second partition surface 680b. There is a gap between each A gap is formed between the other end 420b and the inner top surface 671a. The diameter of the bolt hole 420c is longer than each of these gaps. Therefore, the length of each gap is shorter than the diameter of the shaft portion of the bolt 520 that is passed through the bolt hole 420c.

According to this, the shaft portion of the bolt 520 is prevented from entering each of the above-described gaps due to, for example, a mistake in bolting the phase stator bus bar to the phase bus bar.

Also, the length in the x direction between the opening region of the window for inserting the bolt 520 on the inner side surface 672a of the second wall 674 and the stator bus bar is shorter than the length of the bolt 520 in the x direction.

This prevents the bolts 520 from falling into a small space due to an imperfection in bolting the phase stator bus bar to the phase bus bar.

Inverter housing 670 is assembled to motor housing 510 in which motor 500 is accommodated. Inverter housing 670 is provided above motor housing 510 in the vertical direction.

Therefore, the small space and the large space are arranged horizontally with the partition wall 677 and the terminal block 650 interposed therebetween. The heat generated in the phase stator bus bar tries to positively transfer the heat to the top wall 671 side in the vertical direction. Due to such a configuration, the heat generated in the phase stator bus bar is suppressed from being transferred to the large space side in which the condenser case 610 and the cooler 630 are accommodated.

Inverter housing 670 with partition 677 is made of a high magnetic permeability material with a higher magnetic permeability than air. According to this, the electromagnetic noise generated in the phase stator bus bar by energization is suppressed from penetrating the inverter 410 housed in a large space. In addition, transmission of this electromagnetic noise through the signal terminal 465 is suppressed.

(Other modifications)
In this embodiment, an example in which an electric unit is employed in the power conversion device 400 included in the in-vehicle system 100 of an electric vehicle is shown. However, the use of the electric unit is not limited to the above example. The electrical unit can be suitably employed in hybrid cars, trucks, drones, home appliances, and the like.

In this embodiment, an example is shown in which the wiring board 464 on which the U-phase magnetic-electric conversion unit 461 to the W-phase magnetic-electric conversion unit 463 are mounted is provided on the terminal block 650 insert-molded for the phase bus bar. However, the terminal board 650 may not be provided with the wiring board 464 on which the magnetoelectric conversion section is mounted. That is, the terminal block 650 may not be provided with a component for detecting current.

Although the present disclosure has been described with reference to examples, it is understood that the present disclosure is not limited to such examples or structures. The present disclosure also includes various modifications and modifications within the equivalent range. In addition, while various combinations and configurations are shown in this disclosure, other combinations and configurations, including single elements, more, or less, are within the scope and spirit of this disclosure. It is.

DESCRIPTION OF SYMBOLS 100... Vehicle-mounted system, 200... Battery, 300... Electro-mechanical integrated unit, 400... Power converter, 410... Inverter, 420... Resin module, 420a... One end, 420b... Other end, 421... U-phase bus bar, 422... V-phase Bus bar 423 W-phase bus bar 440 Switch group 461 U-phase magneto-electric converter 462 V-phase magneto-electric converter 463 W-phase magneto-electric converter 464 Wiring board 465 Signal terminal 500 Motor , 501... U-phase stator bus bar, 502... V-phase stator bus bar, 503... W-phase stator bus bar, 510... Motor housing, 630... Cooler, 650... Terminal block, 670... Inverter housing, 671... Top wall, 671a... Inner top surface, 672...Side wall 672a...Inner surface 677...Partition wall 677b...Second facing surface 678...First partition wall 679...Second partition wall 680...Partition wall 680a...First partition surface 680b...Second partition surface

Claims (11)

an electrical component (410);
A plurality of conductive portions (421 to 423) having one end (420a) connected to the electrical component and the other end (420b) connected to the external terminals (501 to 503), and central portions of each of the plurality of conductive portions a resin module (420) comprising an insulating resin part (650) covering the
A housing (671, 672) having a storage space for storing the electrical component and the resin module, respectively, and at least a part of the storage space is defined as a first region in which the electrical component and one end of the conductive portion are provided. and a case (670) provided with a dividing wall (677) that separates the resin portion from a second region provided with the other end of the conductive portion. the electrical component comprises an electronic element (440) included in a power conversion circuit;
2. The electrical unit of claim 1, wherein a cooler (630) for cooling the electronic device is provided in the first area. The resin portion is provided with sensor portions (461 to 463),
The dividing wall is integrally connected to the housing,
3. The electrical unit of claim 2, wherein said cooler is in thermal communication with said housing. The resin portion is positioned between the first region and the second region, and part of the resin portion is positioned in the first region,
4. The electric unit according to claim 3, wherein the sensor portion is provided at a portion of the resin portion located in the first region. 5. The electric unit according to claim 4, wherein a portion of said dividing wall is positioned between an output terminal (465) electrically connected to said sensor portion and the other end of said conductive portion. The housing has a top wall (671) and a side wall (672) that rises annularly from an inner top surface (671a) of the top wall and surrounds the storage space with an inner surface (672a) on the inner top surface side. ) and
The dividing wall extends along the inner ceiling surface and is connected to two different points on the inner surface. An electrical unit as claimed in any one of the preceding claims, which is divided into a first area and the second area. the other ends of each of the plurality of conductive portions are arranged side by side in a vertical direction intersecting the horizontal direction in which the first region and the second region are arranged and the erecting direction of the dividing wall rising from the inner top surface of the dividing wall;
a bolt hole penetrating in the lateral direction is formed at the other end of each of the plurality of conductive portions;
7. The apparatus according to claim 6, wherein the vertical and vertical gaps between the case and each of the plurality of conductive portions and each of the vertical gaps between the plurality of conductive portions are shorter than the diameter of the bolt hole. electrical unit. By assembling the housing to a housing (510) in which a motor (500) that applies power to the running wheels of the vehicle is housed, the opening of the housing defined on the tip end side of the side wall is closed. An electrical unit according to claim 6 or claim 7. 9. The electric unit according to claim 8, wherein the case is positioned closer to the top plate of the vehicle than the housing. 10. An electric unit according to claim 8 or 9, wherein said external terminals are electrically connected to stator coils of said motor. The electric unit according to any one of claims 1 to 10, wherein the housing is made of a high magnetic permeability material having a magnetic permeability higher than that of air.

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