CN105281541A - 电力电子转换器副边功率电路一体式铜排 - Google Patents

电力电子转换器副边功率电路一体式铜排 Download PDF

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CN105281541A
CN105281541A CN201410328942.2A CN201410328942A CN105281541A CN 105281541 A CN105281541 A CN 105281541A CN 201410328942 A CN201410328942 A CN 201410328942A CN 105281541 A CN105281541 A CN 105281541A
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copper bar
coiling
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CN105281541B (zh
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高喆
付登萌
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United Automotive Electronic Systems Co Ltd
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United Automotive Electronic Systems Co Ltd
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Priority to CN201410328942.2A priority Critical patent/CN105281541B/zh
Priority to EP14897175.7A priority patent/EP3168970A4/en
Priority to US15/324,490 priority patent/US10340076B2/en
Priority to JP2017521271A priority patent/JP6509336B2/ja
Priority to PCT/CN2014/095873 priority patent/WO2016004745A1/zh
Priority to KR1020177003689A priority patent/KR20170029586A/ko
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Abstract

本发明公开了一种电力电子转换器副边功率电路一体式铜排，包括变压器原边绕线铜排、变压器副边绕线铜排、电感绕线铜排、检测电阻连接铜排、驱动电路连接铜排、输出端连接铜排，各铜排注塑固定在一起。本发明的电力电子转换器副边功率电路一体式铜排，装配简便，体积小，成本低，并且与功率器件、磁元件、原边电路连接方便。

Description

电力电子转换器副边功率电路一体式铜排
技术领域
本发明涉及新能源电动车用电力电子转换器，特别涉及一种电力电子转换器副边功率电路一体式铜排。
背景技术
新能源车(EV&HEV，纯电动汽车和混合电动汽车)用电力电子转换器，用于将新能源车用高压电池输出的高压直流电转化为低压直流电。电力电子转换器的原边将高压直流电转化为高压交流电，通过变压器以后，高压交流电转变为低压交流电，转换器的副边将低压交流电转换为低压直流电。
电力电子转换器如图1所示，电力电子转换器副边功率电路如图2所示，包括变压器、电感、功率器件、电阻等，为铜排结构设计带来很大难度，转换器副边功率电路的铜排结构设计存在以下难题：
(1)转换器副边功率电路元器件多、电路复杂，装配复杂；
(2)转换器副边功率电路电流大，铜排发热严重，为降低温升而使得体积庞大，成本偏高；
(3)转换器副边功率器件(如Mosfet)与功率电路的之间的连接不方便；
(4)转换器副边功率电路与磁元件的连接复杂且磁元件价格昂贵；
(5)磁元件原边绕线与转换器原边电路难以连接。
发明内容
本发明要解决的技术问题是提供一种电力电子转换器副边功率电路一体式铜排，装配简便，体积小，成本低，并且与功率器件、磁元件、原边电路连接方便。
为解决上述技术问题，本发明提供的电力电子转换器副边功率电路一体式铜排，包括变压器原边绕线铜排、变压器副边绕线铜排、电感绕线铜排、检测电阻连接铜排、驱动电路连接铜排、输出端连接铜排；
所述变压器原边绕线铜排、变压器副边绕线铜排、电感绕线铜排、检测电阻连接铜排、驱动电路连接铜排、输出地端连接铜排注塑固定在一起。
较佳的，所述变压器原边绕线铜排，包括原边绕线、原边绕线上针脚、原边绕线下针脚；
所述原边绕线，多于5圈，并且分布于同一平面；
原边绕线上针脚、原边绕线下针脚分别形成在原边绕线的两端，并且垂直于所述原边绕线所在平面；
所述变压器副边绕线铜排，包括副边绕线、第一D极引脚、第二D极引脚、副边绕线上针脚、副边绕线下针脚；
所述副边绕线，包括副边上圈铜排、副边下圈铜排，副边上圈铜排、副边下圈铜排均呈开口环状，副边上圈铜排、副边下圈铜排分布于上下两个平面，副边上圈铜排、副边下圈铜排的一端结合并形成中间抽头，另一端分别向前延伸；
第一D极引脚、副边绕线上针脚形成在副边上圈铜排的向前延伸段，并且第一D极引脚位于副边绕线上针脚前方；
第二D极引脚、副边绕线下针脚形成在副边下圈铜排的向前延伸段，并且第二D极引脚位于副边绕线下针脚前方；
第一D极引脚、第二D极引脚、平行于副边上圈铜排及副边下圈铜排所在平面；
副边绕线上针脚、副边绕线下针脚垂直于副边上圈铜排及副边下圈铜排所在平面；
所述电感绕线铜排，包括电感绕线、低压输出连接头及低压输出针脚；
所述电感绕线，包括电感上圈铜排、电感下圈铜排，电感上圈铜排、电感下圈铜排均呈开口环状，电感上圈铜排、电感下圈铜排分布于上下两个平面，电感上圈铜排、电感下圈铜排的一端结合，电感下圈铜排的另一端向前延伸，电感上圈铜排的另一端向右延伸；
电感上圈铜排的向右延伸段形成有一副边绕线连接头；
电感下圈铜排的向前延伸段形成有所述低压输出连接头及低压输出针脚；
所述低压输出针脚垂直于电感上圈铜排及电感下圈铜排所在平面；
所述检测电阻连接铜排，呈长条形，中部形成有一接地针脚及两个S极引脚，左端形成有前检电阻连接头；接地针脚垂直于S极引脚；
所述驱动电路连接铜排，包括一G极引脚、一G极针脚，所述G极引脚两端下弯，所述G极针脚位于所述G极引脚中部左侧，所述G极针脚垂直于所述G极引脚；
所述输出地端连接铜排，中部形成有接地针脚，前端左方形成有输出地端连接头，后端右方形成有后检测电阻连接头；
所述变压器副边绕线铜排，位于所述变压器原边绕线铜排上方，原边绕线中心同副边绕线中心相对应；
所述电感绕线铜排，位于所述变压器副边绕线铜排及变压器原边绕线铜排的左侧，所述电感绕线铜排的副边绕线连接头同所述变压器副边绕线铜排的中间抽头电气连接；
所述检测电阻连接铜排，位于所述变压器副边绕线铜排前侧，其两个S极引脚同所述变压器副边绕线铜排的两个D极引脚、两个驱动电路连接铜排的G极引脚，依次间隔排列，形成两组功率器件连接引脚；
所述输出地端连接铜排，位于所述电感绕线铜排前侧及所述检测电阻连接铜排左侧；
原边绕线上针脚、原边绕线下针脚、副边绕线上针脚、副边绕线下针脚、低压输出针脚、接地针脚、G极针脚，探出塑料上表面；
D极引脚、S极引脚、G极引脚、前检测电阻连接头、后检测电阻连接头、低压输出连接头、输出地端连接头均露在塑料外。
较佳的，所述电力电子转换器副边功率电路一体式铜排的底面裸露在塑料外。
较佳的，所述原边绕线，呈矩形环状；
副边上圈铜排、副边下圈铜排均呈开口矩形环状；
电感上圈铜排、电感下圈铜排均呈开口矩形环状。
较佳的，两个检测电阻连接头、低压输出连接头、输出地端连接头均形成有圆孔；
检测电阻通过螺钉连接两个检测电阻连接头之间；
低压输出连接头、输出地端连接头采用压铆螺母与接口铜排作对接。
本发明的电力电子转换器副边功率电路一体式铜排，通过注塑方式将各铜排结构件集成于一体，将变压器与电感的铜排绕线结构也一并集成，各结构件注塑成一体式铜排，与检测电阻及电流输出端的可以通过压装压铆螺母以实现螺钉连接，功率电路与控制电路和高压电路的连接可以通过垂直针脚和PCB间的选择焊接实现，功率器件(如Mosfet)的各引脚与一体式铜排之间可以采用激光焊接方便的实现电气连接，适当位置注塑衬套，以保证对一体式铜排的螺钉固定，功率电路铜排底面裸露，铜排可以通过绝缘导热垫片与冷却板贴合，冷却板为铜排直接散热，显著降低铜排温升，从而缩小铜排截面尺寸，减小体积。
本发明的电力电子转换器副边功率电路一体式铜排，将电力电子转换器副边功率电路中各铜排集成于一体，便于生产与装配；将变压器与电感的绕线线圈集成进一体式铜排，简化了变压器、电感和一体式铜排的连接结构；变压器原边绕线采用冲压铜排制作，铜排与控制电路板(PCB)之间采用针脚进行选择焊接，简化了变压器原边绕线与PCB的连接；功率元件(Mosfet)与一体式铜排可以通过激光焊接实现连接；将各铜排结构件注塑为一体后，与磁芯结构件相组合构成变压器及电感等磁元件，实现磁元件相应的功能，可以额外设计并安装适当的磁芯结构，与绕线安装组合以实现磁元件功能，无须特别购买功率磁元件，显著节省物料成本。
附图说明
为了更清楚地说明本发明的技术方案，下面对本发明所需要使用的附图作简单的介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1是电力电子转换器电路图；
图2是电力电子转换器副边功率电路；
图3是本发明的电力电子转换器副边功率电路一体式铜排的变压器原边绕线铜排俯视图；
图4是本发明的电力电子转换器副边功率电路一体式铜排的变压器原边绕线铜排左视图；
图5是本发明的电力电子转换器副边功率电路一体式铜排的变压器原边绕线铜排正视图；
图6是本发明的电力电子转换器副边功率电路一体式铜排的变压器原边绕线铜排立体图；
图7是本发明的电力电子转换器副边功率电路一体式铜排的变压器副边绕线铜排俯视图；
图8是本发明的电力电子转换器副边功率电路一体式铜排的变压器副边绕线铜排左视图；
图9是本发明的电力电子转换器副边功率电路一体式铜排的变压器副边绕线铜排正视图；
图10是本发明的电力电子转换器副边功率电路一体式铜排的变压器副边绕线铜排立体图；
图11是本发明的电力电子转换器副边功率电路一体式铜排的电感绕线铜排俯视图；
图12是本发明的电力电子转换器副边功率电路一体式铜排的电感绕线铜排左视图；
图13是本发明的电力电子转换器副边功率电路一体式铜排的电感绕线铜排正视图；
图14是本发明的电力电子转换器副边功率电路一体式铜排的电感绕线铜排立体图；
图15是本发明的电力电子转换器副边功率电路一体式铜排的检测电阻连接铜排俯视图；
图16是本发明的电力电子转换器副边功率电路一体式铜排的检测电阻连接铜排左视图；
图17是本发明的电力电子转换器副边功率电路一体式铜排的检测电阻连接铜排正视图；
图18是本发明的电力电子转换器副边功率电路一体式铜排的检测电阻连接铜排立体图；
图19是本发明的电力电子转换器副边功率电路一体式铜排的驱动电路连接铜排俯视图；
图20是本发明的电力电子转换器副边功率电路一体式铜排的驱动电路连接铜排左视图；
图21是本发明的电力电子转换器副边功率电路一体式铜排的驱动电路连接铜排正视图；
图22是本发明的电力电子转换器副边功率电路一体式铜排的驱动电路连接铜排立体图；
图23是本发明的电力电子转换器副边功率电路一体式铜排的输出地端连接铜排俯视图；
图24是本发明的电力电子转换器副边功率电路一体式铜排的输出地端连接铜排左视图；
图25是本发明的电力电子转换器副边功率电路一体式铜排的输出地端连接铜排正视图；
图26是本发明的电力电子转换器副边功率电路一体式铜排的输出地端连接铜排立体图；
图27是本发明的电力电子转换器副边功率电路一体式铜排的俯视图；
图28是本发明的电力电子转换器副边功率电路一体式铜排的立体图；
图29是本发明的电力电子转换器副边功率电路一体式铜排的塑料内部的铜排结构立体图；
图30是本发明的电力电子转换器副边功率电路一体式铜排激光焊接Mosfet后的俯视图；
图31是本发明的电力电子转换器副边功率电路一体式铜排激光焊接Mosfet后的正面立体图；
图32是本发明的电力电子转换器副边功率电路一体式铜排激光焊接Mosfet后的仰视图；
图33是本发明的电力电子转换器副边功率电路一体式铜排激光焊接Mosfet后的背面立体图。
具体实施方式
下面将结合附图，对本发明中的技术方案进行清楚、完整的描述，显然，所描述的实施例是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其它实施例，都属于本发明保护的范围。
电力电子转换器副边功率电路一体式铜排，包括变压器原边绕线铜排1、变压器副边绕线铜排2、电感绕线铜排3、检测电阻连接铜排4、驱动电路连接铜排5、输出端连接铜排6；
所述变压器原边绕线铜排1、变压器副边绕线铜排2、电感绕线铜排3、检测电阻连接铜排4、驱动电路连接铜排5、输出地端连接铜排6注塑固定在一起，如图27、图28、图29、图30、图31、图32、图33所示。
所述变压器原边绕线铜排1，如图3、图4、图5、图6所示，包括一原边绕线11、原边绕线上针脚12,原边绕线下针脚13；
所述原边绕线11，多于5圈，并且分布于同一平面；
原边绕线上针脚12、原边绕线下针脚13分别形成在原边绕线11的两端，并且垂直于所述原边绕线所在平面；
所述变压器副边绕线铜排2，如图7、图8、图9、图10所示，包括一副边绕线21、第一D极引脚25、第二D极引脚26、副边绕线上针脚22、副边绕线下针脚23；
所述副边绕线21，包括副边上圈铜排、副边下圈铜排，副边上圈铜排、副边下圈铜排均呈开口环状，副边上圈铜排、副边下圈铜排分布于上下两个平面，副边上圈铜排、副边下圈铜排的一端结合并形成中间抽头24，另一端分别向前延伸；
第一D极引脚25、副边绕线上针脚22形成在副边上圈铜排的向前延伸段，并且第一D极引脚25位于副边绕线上针脚22前方；
第二D极引脚26、副边绕线下针脚23形成在副边下圈铜排的向前延伸段，并且第二D极引脚26位于副边绕线下针脚23前方；
第一D极引脚25、第二D极引脚26平行于副边上圈铜排及副边下圈铜排所在平面；
副边绕线上针脚22、副边绕线下针脚23垂直于副边上圈铜排及副边下圈铜排所在平面；
所述电感绕线铜排3，如图11、图12、图13、图14所示，包括电感绕线31、低压输出连接头35及低压输出针脚32；
所述电感绕线31，包括电感上圈铜排、电感下圈铜排，电感上圈铜排、电感下圈铜排均呈开口环状，电感上圈铜排、电感下圈铜排分布于上下两个平面；电感上圈铜排、电感下圈铜排的一端结合，电感下圈铜排的另一端向前延伸，电感上圈铜排的另一端向右延伸；
电感上圈铜排的向右延伸段形成有一副边绕线连接头34；
电感下圈铜排的向前延伸段形成有所述低压输出连接头35及低压输出针脚32；
所述低压输出针脚32垂直于电感上圈铜排及电感下圈铜排所在平面；
所述检测电阻连接铜排4，如图15、图16、图17、图18所示，呈长条形，中部形成有一接地针脚42及两个S极引脚45，左端形成有前检测电阻连接头44；接地针脚42垂直于S极引脚45；
所述驱动电路连接铜排5，如图19、图20、图21、图22所示，包括一G极引脚55、一G极针脚52，所述G极引脚55两端下弯，所述G极针脚52位于所述G极引脚55中部左侧，所述G极针脚52垂直于所述G极引脚55；
所述输出地端连接铜排6，如图23、图24、图25、图26所示，中部形成有接地针脚62，前端左方形成有输出地端连接头65，后端右方形成有后检测电阻连接头66，
所述变压器副边绕线铜排2，位于所述变压器原边绕线铜排1上方，原边绕线11中心同副边绕线21中心相对应；
所述电感绕线铜排3，位于所述变压器副边绕线铜排2及变压器原边绕线铜排1的左侧，所述电感绕线铜排3的副边绕线连接头34同所述变压器副边绕线铜排2的中间抽头24电气连接；
所述检测电阻连接铜排4，位于所述变压器副边绕线铜排2前侧，其两个S极引脚45同所述变压器副边绕线铜排2的两个D极引脚25,26、两个驱动电路连接铜排5的G极引脚55，依次间隔排列，形成两组功率器件连接引脚；
所述输出地端连接铜排6，位于所述电感绕线铜排3前侧及所述检测电阻连接铜排4左侧；
原边绕线上针脚12、原边绕线下针脚13、副边绕线上针脚22、副边绕线下针脚23、低压输出针脚32、接地针脚42、G极针脚52，探出塑料上表面；
D极引脚25，26、S极引脚45、G极引脚55、前检测电阻连接头44、后检测电阻连接头66、低压输出连接头35、输出地端连接头65均露在塑料外。
较佳的，所述电力电子转换器副边功率电路一体式铜排的底面裸露在塑料外。
较佳的，所述原边绕线11呈矩形环状；副边上圈铜排、副边下圈铜排均呈开口矩形环状；电感上圈铜排、电感下圈铜排均呈开口矩形环状。
较佳的，前检测电阻连接头44、后检测电阻连接头66、低压输出连接头35、输出地端连接头65均形成有圆孔；
检测电阻通过螺钉连接两个检测电阻连接头之间；
低压输出连接头、输出地端连接头采用压铆螺母与接口铜排作对接。
本发明的电力电子转换器副边功率电路一体式铜排，通过注塑方式将各铜排结构件集成于一体，将变压器与电感的铜排绕线结构也一并集成，各结构件注塑成一体式铜排，与检测电阻及电流输出端的可以通过压装压铆螺母以实现螺钉连接，功率电路与控制电路和高压电路的连接可以通过垂直针脚和PCB间的选择焊接实现，功率器件(如Mosfet)的各引脚与一体式铜排之间可以采用激光焊接方便的实现电气连接，适当位置注塑衬套，以保证对一体式铜排的螺钉固定，功率电路铜排底面裸露，铜排可以通过绝缘导热垫片与冷却板贴合，冷却板为铜排直接散热，显著降低铜排温升，从而缩小铜排截面尺寸，减小体积。
本发明的电力电子转换器副边功率电路一体式铜排，将电力电子转换器副边功率电路中各铜排集成于一体，便于生产与装配；将变压器与电感的绕线线圈集成进一体式铜排，简化了变压器、电感和一体式铜排的连接结构；变压器原边绕线采用冲压铜排制作，铜排与控制电路板(PCB)之间采用针脚进行选择焊接，简化了变压器原边绕线与PCB的连接；功率元件(Mosfet)与一体式铜排可以通过激光焊接实现连接；将各铜排结构件注塑为一体后，与磁芯结构件相组合构成变压器及电感等磁元件，实现磁元件相应的功能，可以额外设计并安装适当的磁芯结构，与绕线安装组合以实现磁元件功能，无须特别购买功率磁元件，显著节省物料成本。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明保护的范围之内。

Claims (5)

1.一种电力电子转换器副边功率电路一体式铜排，其特征在于，包括变压器原边绕线铜排、变压器副边绕线铜排、电感绕线铜排、检测电阻连接铜排、驱动电路连接铜排、输出端连接铜排；
所述变压器原边绕线铜排、变压器副边绕线铜排、电感绕线铜排、检测电阻连接铜排、驱动电路连接铜排、输出地端连接铜排注塑固定在一起。
2.根据权利要求1所述的电力电子转换器副边功率电路一体式铜排，其特征在于，
所述变压器原边绕线铜排，包括原边绕线、原边绕线上针脚、原边绕线下针脚；
所述原边绕线，多于5圈，并且分布于同一平面；
原边绕线上针脚、原边绕线下针脚分别形成在原边绕线的两端，并且垂直于所述原边绕线所在平面；
所述变压器副边绕线铜排，包括副边绕线、第一D极引脚、第二D极引脚、副边绕线上针脚、副边绕线下针脚；
所述副边绕线，包括副边上圈铜排、副边下圈铜排，副边上圈铜排、副边下圈铜排均呈开口环状，副边上圈铜排、副边下圈铜排分布于上下两个平面，副边上圈铜排、副边下圈铜排的一端结合并形成中间抽头，另一端分别向前延伸；
第一D极引脚、副边绕线上针脚形成在副边上圈铜排的向前延伸段，并且第一D极引脚位于副边绕线上针脚前方；
第二D极引脚、副边绕线下针脚形成在副边下圈铜排的向前延伸段，并且第二D极引脚位于副边绕线下针脚前方；
第一D极引脚、第二D极引脚、平行于副边上圈铜排及副边下圈铜排所在平面；
副边绕线上针脚、副边绕线下针脚垂直于副边上圈铜排及副边下圈铜排所在平面；
所述电感绕线铜排，包括电感绕线、低压输出连接头及低压输出针脚；
所述电感绕线，包括电感上圈铜排、电感下圈铜排，电感上圈铜排、电感下圈铜排均呈开口环状，电感上圈铜排、电感下圈铜排分布于上下两个平面，电感上圈铜排、电感下圈铜排的一端结合，电感下圈铜排的另一端向前延伸，电感上圈铜排的另一端向右延伸；
电感上圈铜排的向右延伸段形成有一副边绕线连接头；
电感下圈铜排的向前延伸段形成有所述低压输出连接头及低压输出针脚；
所述低压输出针脚垂直于电感上圈铜排及电感下圈铜排所在平面；
所述检测电阻连接铜排，呈长条形，中部形成有一接地针脚及两个S极引脚，左端形成有前检电阻连接头；接地针脚垂直于S极引脚；
所述驱动电路连接铜排，包括一G极引脚、一G极针脚，所述G极引脚两端下弯，所述G极针脚位于所述G极引脚中部左侧，所述G极针脚垂直于所述G极引脚；
所述输出地端连接铜排，中部形成有接地针脚，前端左方形成有输出地端连接头，后端右方形成有后检测电阻连接头；
所述变压器副边绕线铜排，位于所述变压器原边绕线铜排上方，原边绕线中心同副边绕线中心相对应；
所述电感绕线铜排，位于所述变压器副边绕线铜排及变压器原边绕线铜排的左侧，所述电感绕线铜排的副边绕线连接头同所述变压器副边绕线铜排的中间抽头电气连接；
所述检测电阻连接铜排，位于所述变压器副边绕线铜排前侧，其两个S极引脚同所述变压器副边绕线铜排的两个D极引脚、两个驱动电路连接铜排的G极引脚，依次间隔排列，形成两组功率器件连接引脚；
所述输出地端连接铜排，位于所述电感绕线铜排前侧及所述检测电阻连接铜排左侧；
原边绕线上针脚、原边绕线下针脚、副边绕线上针脚、副边绕线下针脚、低压输出针脚、接地针脚、G极针脚，探出塑料上表面；
D极引脚、S极引脚、G极引脚、前检测电阻连接头、后检测电阻连接头、低压输出连接头、输出地端连接头均露在塑料外。
3.根据权利要求2所述的电力电子转换器副边功率电路一体式铜排，其特征在于，
所述电力电子转换器副边功率电路一体式铜排的底面裸露在塑料外。
4.根据权利要求3所述的电力电子转换器副边功率电路一体式铜排，其特征在于，
所述原边绕线，呈矩形环状；
副边上圈铜排、副边下圈铜排均呈开口矩形环状；
电感上圈铜排、电感下圈铜排均呈开口矩形环状。
5.根据权利要求3所述的电力电子转换器副边功率电路一体式铜排，其特征在于，
两个检测电阻连接头、低压输出连接头、输出地端连接头均形成有圆孔；
检测电阻通过螺钉连接两个检测电阻连接头之间；
低压输出连接头、输出地端连接头采用压铆螺母与接口铜排作对接。
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