CN116830820A

CN116830820A - Power conversion device, motor device, and vehicle

Info

Publication number: CN116830820A
Application number: CN202280011800.6A
Authority: CN
Inventors: 斋藤恒之; 大西本泰; 古津大地; 笠井裕贵; 古水户翔太
Original assignee: Nedco Alexis Co ltd
Current assignee: Nedco Alexis Co ltd
Priority date: 2021-01-29
Filing date: 2022-01-13
Publication date: 2023-09-29
Also published as: DE112022000849T5; WO2022163368A1

Abstract

One embodiment of the power conversion device of the present invention is a power conversion device having an inverter circuit and a converter circuit. The power conversion device includes: a power module having an inverter circuit; a power supply substrate having a converter circuit; a reactor for smoothing a direct current supplied to the converter circuit; a flow path forming body in which the refrigerant flows; and a case for housing the power module, the power supply substrate, the reactor, and the flow path forming body. The flow channel forming body has: a first cooling plate; and a second cooling plate intersecting the first cooling plate and connected to the first cooling plate. The power supply substrate is cooled by a refrigerant disposed on one surface side of the first cooling plate. The reactor is cooled by a refrigerant disposed on one surface side of the second cooling plate.

Description

Power conversion device, motor device, and vehicle

Technical Field

The present invention relates to a power conversion device, a motor device, and a vehicle.

Background

In recent years, development of a power conversion device for a motor and a generator mounted in an electric vehicle or a hybrid vehicle has been advanced. Since such power conversion devices include heat generating components, they are required to be cooled appropriately. For example, patent document 1 discloses a structure in which a flow path through which a refrigerant flows is provided in a wall surface of a casing, and a heat generating component is cooled by the refrigerant.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open publication No. 2019-195260

Disclosure of Invention

Technical problem to be solved by the invention

In the conventional power conversion device, since the refrigerant flows on the wall surface of the case, it is necessary to dispose the heat generating component along the inner wall surface of the case.

In view of the above, an object of the present invention is to provide a power conversion device, a motor device, and a vehicle, which can achieve efficient cooling and can reduce the size of the entire device as compared with a case where a refrigerant flows on a wall surface of a casing.

Technical proposal for solving the technical problems

One embodiment of the power conversion device of the present invention is a power conversion device having an inverter circuit and a converter circuit. The power conversion device includes: a power module having the inverter circuit; a power supply substrate having the converter circuit; a reactor for smoothing a direct current supplied to the converter circuit; a flow path forming body in which the refrigerant flows; and a case accommodating the power module, the power supply board, the reactor, and the flow path forming body. The flow channel forming body has: a first cooling plate; and a second cooling plate intersecting the first cooling plate and connected to the first cooling plate. The power supply board is cooled by the refrigerant disposed on one surface side of the first cooling plate. The reactor is cooled by the refrigerant disposed on one surface side of the second cooling plate.

One embodiment of the motor device of the present invention includes the power conversion device described above.

One embodiment of the vehicle of the present invention includes the motor device described above.

Effects of the invention

According to one aspect of the present invention, a power conversion device, a motor device, and a vehicle that can achieve efficient cooling and that can be made smaller overall than a case where a refrigerant flows on a wall surface of a casing can be provided.

Drawings

Fig. 1 is a circuit block diagram of a motor device according to an embodiment.

Fig. 2 is a schematic diagram showing a longitudinal section of a power conversion device according to an embodiment.

Fig. 3 is a perspective view of a reactor according to an embodiment.

Detailed Description

Hereinafter, a power conversion device 10, a motor device 1, and a vehicle 9 according to an embodiment of the present invention will be described with reference to the drawings. In the drawings below, the scale, the number, and the like of each structure may be different from those of the actual structure in order to facilitate understanding of each structure.

In the following description, the direction of gravity is specified based on the positional relationship when the power conversion device 10 is mounted on a vehicle on a horizontal road surface. The posture of the power conversion device 10 in this specification is an example, and is not limited to the posture in which the power conversion device 10 is actually mounted.

Fig. 1 is a circuit block diagram of a motor apparatus 1. The motor device 1 of the present embodiment is mounted on a vehicle 9 such as a Hybrid Electric Vehicle (HEV) or a plug-in hybrid electric vehicle (PHV) that uses an engine and a motor as power sources. The motor device 1 may be mounted on an Electric Vehicle (EV) having no engine.

The vehicle 9 of the present embodiment includes a motor device 1, an engine (not shown), and drive wheels (not shown). The motor device 1 further includes: a generator 3 driven by an engine not shown; a battery 4 as a direct current power supply charged by the generator 3; the motor 2 for driving a driving wheel, not shown, is driven by using at least one of the battery 4 and the generator 3 as a power source.

The power conversion device 10 boosts a dc voltage supplied from the battery 4 and converts the boosted dc voltage into an ac voltage, supplies the converted ac voltage to the motor 2 to drive the motor 2, converts a voltage at the time of regenerating the motor 2 into a dc voltage, and then lowers the dc voltage and supplies the dc voltage to the battery 4. The power conversion device 10 converts the voltage generated by the generator 3 into a dc voltage, and then steps down the dc voltage to supply the dc voltage to the battery 4, or drives the motor 2 with the voltage generated by the generator 3.

Hereinafter, each configuration of the power conversion device 10 will be described in detail.

The motor 2 is mechanically connected to a reduction mechanism (not shown). The motor 2 drives the driving wheels of the vehicle 9 via a reduction mechanism. The generator 3 is mechanically connected to a reduction mechanism. The generator 3 functions as a regenerative brake for driving the vehicle 9, and generates electric power based on energy at the time of deceleration. The motor 2 and the generator 3 of the present embodiment are 3-phase motors, but may be 4-phase or more multi-phase motors. The motor 2 and the generator 3 are connected to a power conversion device 10, respectively. The battery 4 is, for example, a secondary battery or an electric double layer capacitor. The battery 4 is connected to the power conversion device 10. The battery 4 supplies electric power to the motor 2 via the power conversion device 10. Further, electric power is supplied from the generator 3 to the battery 4 via the power conversion device 10.

The power conversion device 10 includes a converter circuit 13, a motor inverter circuit (inverter circuit) 11, and a generator inverter circuit (inverter circuit) 12. The converter circuit 13 is a so-called DC/DC converter. The converter circuit 13 converts the voltage of the direct current supplied from the battery 4. The motor inverter circuit 11 converts the dc current supplied from the converter circuit 13 into an ac current and supplies the ac current to the motor 2. The generator inverter circuit 12 converts the electric power generated by the generator 3 from ac current to dc current, and charges the battery 4.

In the following description, the motor inverter circuit 11 and the generator inverter circuit 12 will be simply referred to as inverter circuits 11 and 12 without distinction.

Fig. 2 is a schematic diagram of a longitudinal section of the power conversion device 10.

Fig. 2 shows a first direction D1, a second direction D2 and a third direction D3.

In the present embodiment, the first direction D1 is the up-down direction, one side of the first direction D1 is the upper side, and the other side of the first direction D1 is the lower side.

The second direction D2 is a direction orthogonal to the first direction D1. In the present embodiment, the second direction D2 is one direction along the horizontal plane. One side of the second direction D2 is the right side in fig. 2, and the other side of the second direction D2 is the left side in fig. 2.

The third direction D3 is a direction along the horizontal direction, and is a direction orthogonal to the first direction D1 and the second direction D2. That is, the first direction D1, the second direction D2, and the third direction D3 are mutually orthogonal directions, respectively.

The power conversion device 10 includes: an inverter control board (control board) 41, a converter control board (control board) 42, a power supply board 43, a first drive board 45, a second drive board 46, a motor power module 21, a generator power module 22, a reactor 30, a reactor base (second heat conductive plate) 35, a capacitor module 15, a shield plate 50, a heat conductive plate (first heat conductive plate) 55, a flow path formation body 60, and a housing 19. The flow channel forming body 60 includes a first cooling plate 61, a second cooling plate 62, a third cooling plate 63, and a connecting pipe 64.

The case 19 houses the inverter control board 41, the converter control board 42, the power supply board 43, the first drive board 45, the second drive board 46, the motor power module 21, the generator power module 22, the reactor 30, the reactor base 35, the capacitor module 15, the shield plate 50, the heat conductive plate 55, and the flow channel forming body 60.

As shown in fig. 1, the motor power module 21 includes a motor inverter circuit 11. On the other hand, the generator power module 22 includes the generator inverter circuit 12. The motor inverter circuit 11 and the generator inverter circuit 12 convert a dc voltage to an ac voltage or an ac voltage to a dc voltage.

In the following description, the motor power module 21 and the generator power module 22 will be simply referred to as power modules 21 and 22 without distinction.

The motor power module 21 and the generator power module 22 each have six first switching elements (switching elements) 16. In the case of the present embodiment, the first switching element 16 is an insulated gate bipolar transistor (IGBT: insulated Gate Bipolar Transistor). That is, the power modules 21 and 22 have insulated gate bipolar transistors. By using an insulated gate bipolar transistor as the first switching element 16, the power modules 21, 22 can be configured relatively inexpensively. The inverter circuits 11 and 12 are Pulse Width Modulation (PWM) inverters each including a bridge circuit for bridge-connecting the first switching element 16.

As shown in fig. 2, the motor power module 21 and the generator power module 22 are disposed along a horizontal plane (a plane orthogonal to the first direction D1). The generator power module 22 is laminated on the upper side of the motor power module 21 via a third cooling plate 63. That is, the third cooling plate 63 is sandwiched between the motor power module 21 and the generator power module 22. As described later, the third cooling plate 63 cools the motor power module 21 and the generator power module 22 by the refrigerant L flowing therein.

A first drive board 45 is disposed below the motor power module 21. A second drive board 46 is disposed above the generator power module 22. The substrate bodies 45a, 46a of the first and second drive substrates 45, 46 are arranged along a horizontal plane (a plane orthogonal to the first direction D1).

The first drive board 45 is connected to the motor power module 21 and the inverter control board 41. Similarly, the second drive board 46 is connected to the generator power module 22 and the inverter control board 41. The first driving substrate 45 and the second driving substrate 46 generate driving power of the first switching element 16 based on the control signal for controlling the first switching element 16 generated by the inverter control substrate 41, respectively.

As shown in fig. 1, the power supply substrate 43 has a converter circuit 13. The converter circuit 13 boosts the voltage supplied from the battery 4 or reduces the voltage supplied to the battery 4. A reactor 30 is connected in series between the converter circuit 13 and the battery 4. In addition, a capacitor module 15 is connected in parallel on the downstream side of the converter circuit 13.

The power supply substrate 43 has two second switching elements (switching elements) 17 and a substrate main body (omitted in fig. 1) to which the second switching elements 17 are mounted. In the case of the present embodiment, the second switching element 17 is a transistor including silicon carbide (SiC). That is, the power supply substrate 43 has a transistor including silicon carbide. By adopting a transistor including silicon carbide as the second switching element 17, the conversion efficiency of the voltage in the second switching element 17 can be improved, and heat generation of the power supply substrate 43 can be suppressed. The converter circuit 13 includes a chopper circuit to which the second switching element 17 is connected.

As shown in fig. 2, the substrate main body 43a of the power supply substrate 43 is disposed along a horizontal plane (a plane orthogonal to the first direction D1). That is, the power supply substrate 43 is arranged with the vertical direction (first direction D1) as the plate thickness direction. A first cooling plate 61 is disposed on the lower side (the other side in the first direction D1) of the power supply substrate 43 via a heat conductive plate 55.

The heat conductive plate 55 is made of a metal material having high heat conductivity. Examples of the material constituting the heat conductive plate 55 include an aluminum alloy and a copper alloy. As a material constituting the heat conductive plate 55, a magnetic shielding material (for example, an aluminum alloy) is more preferably used.

The heat conductive plate 55 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the heat conductive plate 55 is arranged with the up-down direction (first direction D1) as the plate thickness direction. The heat conductive plate 55 is stacked on the power supply substrate 43 along the up-down direction (first direction D1).

The heat conductive plate 55 is in contact with the power supply substrate 43. More specifically, the heat conductive plate 55 is in contact with the second switching element 17 (not shown in fig. 2) mounted on the power supply substrate 43. The heat conductive plate 55 is cooled by the refrigerant L flowing inside the first cooling plate 61. The power supply substrate 43 is cooled by the refrigerant L via the heat conductive plate 55. The heat conductive plate 55 may have a fin on a surface contacting the refrigerant L.

As shown in fig. 1, the capacitor module 15 is connected in parallel between the converter circuit 13 and the inverter circuits 11, 12. The capacitor module 15 smoothes the dc current supplied from the converter circuit 13 to the motor inverter circuit 11 in the capacitor element 15 a.

As shown in fig. 2, the capacitor module 15 includes a capacitor element 15a and a capacitor case 15b accommodating the capacitor element 15 a. The capacitor module 15 is disposed on one side (right side in fig. 2) in the second direction D2 with respect to the motor power module 21, the generator power module 22, and the third cooling plate 63. The capacitor module 15 is disposed on the other side (left side in fig. 2) in the second direction D2 with respect to the second cooling plate 62.

The capacitor module 15 is in contact with the second cooling plate 62 and the third cooling plate 63. The second cooling plate 62 and the third cooling plate 63 are cooled by the refrigerant L flowing therein. According to the present embodiment, the capacitor module 15 is effectively cooled from both sides in the second direction D2 by being in contact with the second cooling plate 62 and the third cooling plate 63 disposed on one side and the other side of the second direction D2, respectively. This can suppress the capacitor module 15 from becoming high temperature, and can improve the reliability of the capacitor element 15 a.

As shown in fig. 1, the reactor 30 is connected in series between the battery 4 and the converter circuit 13. The reactor 30 smoothes the direct current supplied from the battery 4 to the converter circuit 13.

As shown in fig. 2, the reactor 30 is disposed on one side (right side in fig. 2) in the second direction D2 with respect to the power modules 21, 22 and the third cooling plate 63. The capacitor module 15, the third cooling plate 63, and the reactor base 35 are disposed between the reactor 30 and the power modules 21, 22 and the third cooling plate 63.

The reactor 30 is supported by a reactor base 35. The reactor base 35 has a plate-like portion in which the second direction D2 is the plate thickness direction. The reactor base 35 is made of a metal material having high thermal conductivity. Examples of the material constituting the reactor base 35 include materials having excellent thermal conductivity such as aluminum alloy and copper alloy. Further, as a material constituting the reactor base 35, a material (for example, aluminum alloy) for magnetic shielding is more preferably used.

The reactor base 35 is in contact with the reactor 30. The reactor base 35 is cooled by the refrigerant L flowing inside the second cooling plate 62. The reactor 30 is cooled by the refrigerant L via the reactor base 35. The reactor base 35 may have a fin on a contact surface with the refrigerant L.

Fig. 3 is a perspective view of the reactor 30.

The reactor 30 has three coil portions 30a and a reactor case 30b. The coil portion 30a is formed of a wire wound around a central axis J along the up-down direction (first direction D1). The reactor case 30b is made of, for example, a resin material. The reactor case 30b houses three coil portions 30a. The coil portion 30a and the reactor case 30b are located on one side (right side in fig. 2) of the reactor base 35 in the second direction D2. The 3 coil portions 30a are arranged along the surface direction of the reactor base 35.

A part of the reactor base 35 may protrude in the thickness direction and may support the periphery of the reactor case 30b.

As shown in fig. 2, the inverter control board 41 and the converter control board 42 are disposed on the upper side (the side in the first direction D1) with respect to the power modules 21 and 22.

In the following description, the inverter control board 41 and the converter control board 42 will be simply referred to as control boards 41 and 42 without distinction therebetween.

The inverter control board 41 is electrically connected to the motor power module 21 and the generator power module 22 via the first drive board 45 and the second drive board 46. The inverter control board 41 controls the inverter circuits 11, 12. The inverter control board 41 generates control signals for controlling the first switching element 16 of the motor power module 21 and the first switching element 16 of the generator power module 22.

The converter control substrate 42 is electrically connected to the power supply substrate 43. The converter control substrate 42 controls the converter circuit 13 of the power supply substrate 43. The converter control substrate 42 generates a control signal for controlling the second switching element 17 of the power supply substrate 43.

The substrate bodies 45a, 46a of the control substrates 41, 42 are arranged along a horizontal plane (a plane orthogonal to the first direction D1). That is, the control boards 41 and 42 are arranged with the up-down direction (first direction D1) being the board thickness direction. The inverter control board 41 is disposed on the upper side (on the side in the first direction D1) with respect to the converter control board 42.

The control boards 41 and 42 are relatively susceptible to electromagnetic wave noise at high frequencies. The present inventors found that high-frequency electromagnetic wave noise generated from the reactor 30 propagates outward in the radial direction of the central axis J of the reactor 30. According to the present embodiment, the control boards 41 and 42 are located radially outward of the reactor 30 when viewed from the up-down direction (first direction D1). The control boards 41 and 42 are located above the reactor 30 (on the side in the first direction D1). Therefore, according to the present embodiment, high-frequency electromagnetic wave noise propagating radially outward from the reactor 30 hardly reaches the control boards 41 and 42. As a result, the control boards 41 and 42 are less susceptible to electromagnetic wave noise at high frequencies, and the reliability of the control boards 41 and 42 can be improved.

In the present embodiment, the case where the inverter control board 41 and the converter control board 42 are each arranged as described above with respect to the reactor 30 is described. However, by configuring either the inverter control board 41 or the converter control board 42 as described above, the effect of making the control board less susceptible to electromagnetic wave noise can be obtained. That is, if the control board that controls at least one of the inverter circuits 11, 12 and the converter circuit 13 is configured as described above, a certain effect can be obtained for the control board.

According to the present embodiment, the reactor base 35 is disposed between the reactor 30 and the control boards 41 and 42 and the power modules 21 and 22, as viewed from the vertical direction (first direction D1). As a material constituting the reactor base 35, a material (for example, aluminum alloy) for magnetic shielding is preferably used. In this case, the reactor base 35 shields electromagnetic wave noise propagating from the reactor 30 to the radial outside of the center axis J and directed toward the control substrates 41, 42 and the power modules 21, 22. In addition, the electromagnetic wave shielding effect by the reactor base 35 is only an auxiliary effect. Therefore, it is not necessary to thicken the reactor base 35 in order to improve the shielding effect.

In the present embodiment, a second cooling plate 62 extending in the up-down direction (first direction D1) is disposed between the power modules 21 and 22 and the reactor 30. As a material constituting the second cooling plate 62, a material (for example, aluminum alloy) for magnetic shielding is preferably used. In this case, the second cooling plate 62 shields electromagnetic wave noise propagating from the reactor 30 to the radial outside of the center axis J and toward the control substrates 41, 42 and the power modules 21, 22.

In the present embodiment, the capacitor module 15 is disposed between the power modules 21 and 22 and the second cooling plate 62. Therefore, the capacitor module 15 shields electromagnetic wave noise propagating radially outward of the center axis J from the reactor 30 and toward the control substrates 41, 42 and the power modules 21, 22.

In addition, according to the present embodiment, the power modules 21 and 22 are located radially outward of the reactor 30 as viewed from the up-down direction (first direction D1). The power modules 21 and 22 are relatively large-sized components among the components constituting the power conversion device 10. According to the present embodiment, by arranging the power modules 21 and 22 in the above-described configuration, the space inside the housing 19 can be effectively utilized, and the power conversion device 10 can be miniaturized.

In the present embodiment, the central axis J of the coil portion 30a is along the first direction D1. Here, the central axis J "along the first direction D1" includes not only a case where the central axis J is strictly parallel to the first direction D1, but also a case where the central axis J is inclined to at least one of the second direction D2 and the third direction D3 within ±45° with respect to the first direction D1. According to the present embodiment, even if the central axis J of the coil portion 30a is arranged in a posture inclined within a range of ±45° with respect to the up-down direction (first direction D1), the above-described fixed effect can be obtained.

In the present embodiment, the control boards 41 and 42 and the power supply board 43 are stacked in the up-down direction (first direction D1). That is, the power supply substrate 43 is laminated with the control substrates 41 and 42. According to the present embodiment, the control boards 41 and 42 and the power supply board 43 are easily disposed close to each other, and a harness (not shown) for connecting the boards to each other can be shortened. Thereby, electromagnetic wave noise generated from the wire harness can be reduced.

The shielding plate 50 is disposed between the inverter control substrate 41 and the converter control substrate 42. The shielding plate 50 is plate-shaped and disposed along a horizontal plane (a plane orthogonal to the first direction D1). That is, the shield plate 50 is arranged with the up-down direction (first direction D1) as the plate thickness direction. The shielding plate 50 supports the control substrates 41, 42. That is, the inverter control board 41 is fixed to the upper surface of the shielding plate 50, and the converter control board 42 is fixed to the upper surface of the shielding plate 50. The shield plate 50 is fixed to the inner surface of the housing 19.

The shielding plate 50 performs magnetic shielding between the inverter control substrate 41 and the converter control substrate 42. Therefore, the shielding plate 50 suppresses electromagnetic wave noise generated in one of the inverter control board 41 and the converter control board 42 from reaching the other. The shield plate 50 is made of, for example, an aluminum alloy. However, in order to enhance the magnetic shielding effect, a shield plate made of an iron-based alloy may be used for the shield plate 50.

In addition, in the converter control substrate 42 of the present embodiment, both a high voltage region through which a high voltage current flows and a low voltage region through which a low voltage current flows are provided. On the other hand, only a low voltage region through which the low voltage current flows is provided in the inverter control substrate 41. According to the present embodiment, it is possible to suppress electromagnetic wave noise generated in the high voltage region of the converter control substrate 42 from affecting the inverter control substrate 41.

In the present embodiment, the shielding plate 50 covers the entire lower surface of the inverter control substrate 41. That is, the shield plate 50 overlaps the entire inverter control board 41 when viewed from the up-down direction (first direction D1). Thereby, the shielding plate 50 effectively suppresses electromagnetic wave noise from reaching the inverter control substrate 41 from the lower side.

According to the present embodiment, the inverter control board 41 is disposed on the upper side (the side in the first direction D1) of the shielding plate 50, and the converter control board 42 is disposed on the lower side of the shielding plate 50. The inverter control board 41 is more susceptible to high-frequency electromagnetic wave noise from the reactor 30 than the converter control board 42. According to the present embodiment, by disposing the inverter control board 41 above the shield plate 50, electromagnetic wave noise of the reactor 30 located further below the shield plate 50 can be suppressed from reaching the inverter control board 41, and the reliability of the power conversion device 10 can be improved.

The refrigerant L flows inside the flow path forming body 60. The flow channel forming body 60 is a member different from the housing 19. The flow path forming body 60 forms a flow path for the refrigerant L in the casing 19. The refrigerant L flowing through the flow path of the flow path forming body 60 cools the components disposed inside the casing 19.

The flow channel forming body 60 has a first flow channel forming portion 60A and a second flow channel forming portion 60B that can be divided from each other. The first flow path forming portion 60A has a first cooling plate 61 and a second cooling plate 62. On the other hand, the second flow path forming portion 60B has a third cooling plate 63 and a connecting pipe 64. The second flow path forming portion 60B is connected to the first flow path forming portion 60A by connecting the connecting pipe 64 to the first cooling plate 61. That is, the first channel forming portion 60A and the second channel forming portion 60B are connected to each other.

According to the power conversion device 10 of the present embodiment, a plurality of cooling plates 61, 62, 63 are provided inside the housing 19, and these cooling plates 61, 62, 63 are connected to each other. Therefore, the plurality of cooling plates 61, 62, 63 can be disposed in the housing 19 in a complicated manner, and the components in the housing 19 can be cooled effectively.

The first channel forming portion 60A and the second channel forming portion 60B are made of a metal material having high thermal conductivity. Examples of the material constituting the first channel forming portion 60A and the second channel forming portion 60B include an aluminum alloy, a copper alloy, and the like. As a material constituting the first channel forming portion 60A and the second channel forming portion 60B, a magnetic shielding material (for example, an aluminum alloy) is more preferably used.

The refrigerant L flows through the third cooling plate 63 in the order of the connecting pipe 64, the first cooling plate 61, and the second cooling plate 62 in the flow path forming body 60. Hereinafter, each portion of the flow path forming body 60 along the flow of the refrigerant L will be described.

The third cooling plate 63 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the third cooling plate 63 is arranged with the up-down direction (first direction D1) as the plate thickness direction.

The third cooling plate 63 is disposed between the motor power module 21 and the generator power module 22. The third cooling plate 63 cools the motor power module 21 and the generator power module 22 by the refrigerant L flowing therein.

The third cooling plate 63 is provided with a first connection hole 63c, a third recess 63a, a first communication hole 63d, and a 4 th recess 63b. The refrigerant L flows into the inside of the flow path forming body 60 in the first connection hole 63 c.

The first connection hole 63c is opened in the second direction D2. An inflow port 69 of the refrigerant L is connected to an opening of the first connection hole 63 c. The first connection hole 63c is opened to the inner side surface of the third recess 63 a.

The third recess 63a is provided on the lower surface of the third cooling plate 63. The third recess 63a opens to the lower side. That is, the third recess 63a opens to the motor power module 21 side. The third recess 63a is covered by the motor power module 21. The heat sink 21p faces the upper surface of the motor power module 21. The heat sink 21p is disposed inside the third recess 63 a. In the third concave portion 63a, the refrigerant L flows between the fins 21 p.

The first communication hole 63D penetrates the third cooling plate 63 in the up-down direction (first direction D1). The first communication hole 63d opens at the bottom surface of the third recess 63a and the bottom surface of the fourth recess 63b. The first communication hole 63d communicates the third recess 63a and the fourth recess 63b with each other.

The fourth recess 63b is provided on the upper surface of the third cooling plate 63. The fourth recess 63b opens upward. That is, the 4 th concave portion 63b opens to the generator power module 22 side. The fourth recess 63b is covered by the power generator module 22. The heat sink 22p faces the lower surface of the generator power module 22. The heat sink 22p is disposed inside the fourth recess 63b. In the fourth concave portion 63b, the refrigerant L flows between the fins 22 p.

In the present embodiment, the refrigerant L passes through the first connection hole 63c, the third concave portion 63a, the first connection hole 63d, and the fourth concave portion 63b in this order. The refrigerant L cools the motor power module 21 when passing through the third recess 63a, and cools the generator power module 22 when passing through the fourth recess 63b.

According to the present embodiment, by providing the heat radiation fins 21p and 22p to the power modules 21 and 22, the contact area between the power modules 21 and 22 and the refrigerant L can be ensured to be large, and the power modules 21 and 22 can be cooled effectively by the refrigerant L.

In addition, a surface of the third cooling plate 63 facing one side (right side in fig. 2) in the second direction D2 is in contact with the capacitor module 15. Thereby, the third cooling plate 63 cools the capacitor module 15.

The connecting pipe 64 extends in the up-down direction (first direction D1). The connecting pipe 64 connects the third cooling plate 63 and the first cooling plate 61. The refrigerant L moves from the inside of the third cooling plate 63 to the inside of the first cooling plate 61 through the connecting pipe 64.

The first cooling plate 61 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the first cooling plate 61 is arranged with the up-down direction (first direction D1) as the plate thickness direction.

The first cooling plate 61 is disposed along the lower surface of the power supply substrate 43. A heat conductive plate 55 is provided between the first cooling plate 61 and the power supply substrate 43. The first cooling plate 61 cools the power supply substrate 43 by the refrigerant L flowing inside. That is, the power supply substrate 43 is disposed on one surface side of the first cooling plate 61 and cooled by the refrigerant L.

The first cooling plate 61 is provided with a second connection hole 61b, a first recess 61a, and a second communication hole 61c. The refrigerant L passes through the second connection hole 61b, the first concave portion 61a, and the second communication hole 61c in this order.

The second connection hole 61b penetrates in the up-down direction (first direction D1). The second connection hole 61b is opened to the lower side. A connecting pipe 64 is connected to an opening of the second connection hole 61 b. In addition, the second connection hole 61b is opened at the bottom surface 61f of the first concave portion 61 a.

The first concave portion 61a is provided on the lower surface of the first cooling plate 61. The first concave portion 61a opens upward. That is, the first concave portion 61a opens to the power supply substrate 43 side. The refrigerant L flows in the first concave portion 61 a. In addition, the first concave portion 61a is covered with the heat conductive plate 55. The refrigerant L in the first concave portion 61a cools the power supply substrate 43 via the heat conductive plate 55.

The first concave portion 61a has a bottom surface 61f facing the opening side. The bottom surface 61f has an inclined surface 61s. The inclined surface 61s deepens the opening depth toward the downstream side of the refrigerant L. This can reduce the pressure loss of the refrigerant L flowing in the first concave portion 61 a. As a result, the power consumption of the pump that pumps the refrigerant L can be reduced. In the present embodiment, the inclined surface 61s is provided at a part of the bottom surface 61f. However, the entire bottom surface 61f may be an inclined surface whose opening depth is increased toward the downstream side of the refrigerant L.

The second communication hole 61c extends in the second direction D2. The second communication hole 61c opens at a bottom surface 61f of the first recess 61 a. In addition, the second communication hole 61c opens at the bottom surface 62f of the second recess 62a. The second communication hole 61c communicates the first recess 61a and the second recess 62a with each other.

The second cooling plate 62 is plate-shaped and disposed along the up-down direction (first direction D1). The second cooling plate 62 is disposed with the second direction D2 as the plate thickness direction.

The second cooling plate 62 is disposed along the reactor 30. A reactor base 35 is provided between the second cooling plate 62 and the reactor 30. The second cooling plate 62 cools the reactor 30 by the coolant L flowing inside thereof. That is, the reactor 30 is disposed on one surface side of the second cooling plate 62 and cooled by the refrigerant L.

The second cooling plate 62 is provided with a second concave portion 62a and a discharge hole 62b. The refrigerant L sequentially passes through the second concave portion 62a and the discharge hole 62b.

The second concave portion 62a is provided on a surface of the second cooling plate 62 on a side (right side in fig. 2) facing the second direction D2. The second concave portion 62a is open at one side in the second direction D2. That is, the second concave portion 62a opens to the reactor 30 side. The second recess 62a has a bottom surface 62f facing the opening side. The second communication hole 61c extending from the first cooling plate 61 opens at the bottom surface 62f. The refrigerant L flows into the second concave portion 62a via the second communication hole 61c. The refrigerant L flows in the second concave portion 62a. In addition, the second concave portion 62a is covered with the reactor base 35. The refrigerant L in the second concave portion 62a cools the power supply substrate 43 via the reactor base 35.

The surface of the second cooling plate 62 facing the other side (left side in fig. 2) in the second direction D2 is in contact with the capacitor module 15. Thereby, the second cooling plate 62 cools the capacitor module 15.

The discharge hole 62b extends in the up-down direction (first direction D1) from the inner wall surface of the second concave portion 62a. That is, the discharge hole 62b opens to the inner wall surface of the second concave portion 62a. In addition, the discharge hole 62b opens at the lower end portion of the second cooling plate 62. The discharge hole 62b is disposed at the most downstream side of the flow path forming body 60, and discharges the refrigerant L inside the flow path forming body 60. Further, another flow path forming portion may be disposed downstream of the discharge hole 62b.

The first flow path forming portion 60A of the present embodiment includes a first cooling plate 61 and a second cooling plate 62 intersecting each other. That is, the second cooling plate 62 crosses the first cooling plate 61 and is connected to the first cooling plate 61. Here, the first cooling plate 61 and the second cooling plate 62 "cross" means that the first cooling plate 61 and the second cooling plate 62 are arranged along surfaces that are not parallel to each other and are connected to each other.

According to the present embodiment, the first cooling plate 61 and the second cooling plate 62 intersecting each other are arranged inside the housing 19. This improves the degree of freedom in the arrangement of the components in the case 19, as compared with the case where the heat generating element is arranged along the case by providing a flow path in the case itself and cooling the heat generating element. As a result, the components can be effectively disposed in the housing 19, and the overall size can be reduced. In particular, in the present embodiment, since the first cooling plate 61 and the second cooling plate 62 are disposed so as to intersect each other, the flow path forming body 60 can be efficiently disposed in the gap between the respective constituent members of the power conversion device 10.

Here, the larger one of the 2 intersecting angles formed by the first cooling plate 61 and the second cooling plate 62 is referred to as a reflex angle α, and the smaller other is referred to as a minor angle β. The reflex angle α is an angle exceeding 180 °. Each β is an angle less than 180 °. In addition, according to the present embodiment, the first cooling plate 61 and the second cooling plate 62 are orthogonal to each other. Therefore, the reflex angle α is 270 °, and the inferior angle β is 90 °.

According to the present embodiment, the reactor 30 and the distribution board 43 are arranged on the side of the reflex angle α formed by the first cooling board 61 and the second cooling board 62. The power modules 21 and 22 and the capacitor module 15 are disposed on the inferior angle β side formed by the first cooling plate 61 and the second cooling plate 62. According to the present embodiment, by disposing the reactor 30 and the power supply substrate 43 having relatively small thickness dimensions in the heating element on the reflex angle α side of the first flow path forming portion 60A, the power conversion device 10 can be miniaturized. Further, according to the present embodiment, by disposing the relatively large power modules 21 and 22 and the capacitor module 15 in the heating element on the inferior angle β side of the first channel forming portion 60A, the area surrounded by the first cooling plate 61 and the second cooling plate 62 can be effectively utilized, and the power conversion device 10 can be miniaturized. According to the present embodiment, the reactor 30, the power supply substrate 43, the power modules 21 and 22, and the capacitor module 15 can be cooled effectively. According to the present embodiment, the region in which the reactor 30 and the power supply substrate 43 are arranged and the region in which the power modules 21 and 22 and the capacitor module 15 are arranged can be divided by the flow channel forming body 60. This makes it possible to effectively use the interior of the housing 19.

According to the present embodiment, the first cooling plate 61 is disposed between the power supply substrate 43 and the power modules 21, 22. Thereby, the first cooling plate 61 divides the arrangement space of the power supply substrate 43 and the arrangement space of the power modules 21, 22, and suppresses heat exchange therebetween. This can suppress one of the power supply substrate 43 and the power modules 21 and 22 from being heated by the other, and can improve the reliability of the power supply substrate 43 and the power modules 21 and 22.

According to the present embodiment, the second cooling plate 62 is disposed between the reactor 30 and the capacitor module 15. Thereby, the second cooling plate 62 effectively cools the reactor 30 and the capacitor module 15 on both sides. Further, the second cooling plate 62 divides the arrangement space of the reactor 30 and the arrangement space of the capacitor module 15, and suppresses heat exchange therebetween. This can suppress one of the reactor 30 and the capacitor module 15 from being heated by the other, and can improve the reliability of the reactor 30 and the capacitor module 15.

According to the present embodiment, the motor power module 21, the third cooling plate 63, the generator power module 22, the first cooling plate 61, and the power supply substrate 43 form a laminated structure. Therefore, these components can be easily arranged at high density, the internal space of the housing 19 can be effectively utilized, and the entire power conversion device 10 can be miniaturized. The power modules 21 and 22 and the power supply substrate 43 serving as heating elements can be efficiently cooled by using the first cooling plate 61 and the third cooling plate 63. Further, a first cooling plate 61 and a third cooling plate 63 are disposed between the power modules 21 and 22 and the power supply substrate 43, respectively, which are heating elements. Therefore, even if the heating elements are disposed close to each other, the heating elements can be suppressed from being heated by each other, and the reliability of the power modules 21 and 22 and the power supply substrate 43 as the heating elements can be improved.

In the flow path forming body 60 of the present embodiment, the refrigerant L cools the power modules 21 and 22, the power supply substrate 43, and the reactor 30 in order from the upstream side toward the downstream side. In general, the temperature of the heating element of the power conversion device 10 tends to rise in the order of the power modules 21, 22, the power supply substrate 43, and the reactor 30. According to the present embodiment, by cooling the refrigerant L in this order, the refrigerant having a lower temperature can be supplied to the heating element that needs to be cooled more, and the reliability of the power conversion device 10 can be improved.

In general, the motor power module 21 is used at a higher frequency than the generator power module 22, and is likely to be at a higher temperature. According to the present embodiment, the refrigerant L sequentially cools the motor power module 21 and the generator power module 22. Therefore, the motor power module 21 that is easily heated to a high temperature can be suppressed from being heated to a high temperature, and the reliability of the power conversion device 10 can be improved.

While the embodiments of the present invention have been described above, the structures and combinations thereof in the embodiments are examples, and the structures may be added, omitted, substituted, and other modified without departing from the spirit of the present invention. The present invention is not limited to the embodiments.

For example, in the above-described embodiment, the power conversion device 10 having, as power modules, the motor power module 21 connected to the motor 2 and the generator power module 22 connected to the generator 3, respectively, has been described. However, the power conversion device 10 may have only one of the motor power module 21 and the generator power module 22.

In the above embodiment, the case where the inclined surface 61s is provided on the bottom surface of the first concave portion 61a has been described. However, an inclined surface may be provided on the bottom surface of the second concave portion 62a. That is, the inclined surface may have at least one bottom surface of the first concave portion 61a and the second concave portion 62a.

In the above-described embodiment, the case where the heat radiation fins are provided on the power module, the reactor base, and the heat conduction plate has been described, but the shape of the heat radiation fins is not limited as long as the heat radiation area can be increased. For example, a plurality of pin fins or plate fins may be used.

Description of the reference numerals

A motor device, a 2-motor, a 3-generator, a 9-vehicle, a 10-power conversion device, an inverter circuit (inverter circuit) for a 11-motor, an inverter circuit (inverter circuit) for a 12-generator, a 13-converter circuit, a 15-capacitor module, a 19-case, a 21-power module, a 21-motor power module, a 22-generator power module, a 30-reactor, a 30A-coil portion, a 35-reactor base (second heat conduction plate), a 41-inverter control board (control board), a 42-converter control board (control board), a 43-power supply board, a 50-shielding plate, a 55-heat conduction plate (first heat conduction plate), a 60-flow path formation portion, a 60A first-flow path formation portion, a 60B second-flow path formation portion, a 61 first cooling plate, a 61a first recess portion, 61f, a 62f bottom surface, a 61s inclined surface, a 62 second cooling plate, a 62a second recess portion, a 63 third cooling plate, a D1 first direction, a D2 second direction, a J-center axis, L refrigerant, an α -major angle, and β -minor angle.

Claims

1. A power conversion apparatus having an inverter circuit and a converter circuit, comprising:

a power module having the inverter circuit;

a power supply substrate having the converter circuit;

a reactor that smoothes a direct current supplied to the converter circuit;

a flow path forming body in which a refrigerant flows; and

a case that houses the power module, the power supply board, the reactor, and the flow path forming body,

the flow channel forming body has:

a first cooling plate; and

a second cooling plate intersecting and connected to the first cooling plate,

the power supply board is cooled by the refrigerant arranged on one surface side of the first cooling plate,

the reactor is cooled by the refrigerant disposed on one surface side of the second cooling plate.

2. The power conversion device of claim 1, wherein,

the reactor and the power supply substrate are disposed on the reflex angle side of two intersecting angles formed by the first cooling plate and the second cooling plate.

3. A power conversion apparatus according to claim 1 or 2, wherein,

the power module is disposed on a inferior corner side of two intersecting corners formed by the first cooling plate and the second cooling plate.

4. A power conversion apparatus according to any one of claim 1 to 3,

the power module comprises a motor power module connected with the motor and a generator power module connected with the generator respectively,

the flow path forming body has a third cooling plate disposed between the motor power module and the generator power module, the cooling plate cooling the motor power module and the generator power module with the refrigerant,

the motor power module, the third cooling plate, the generator power module, the first cooling plate, and the power supply base plate are formed in a laminated structure.

5. The power conversion device of claim 4, wherein,

comprising a capacitor module for smoothing a direct current supplied to the inverter circuit,

the capacitor module is in contact with the second cooling plate and the third cooling plate.

6. A power conversion device according to claim 4 or 5, wherein,

the flow channel forming body has:

a first flow path forming portion having the first cooling plate and the second cooling plate; and

a second flow path forming portion having the third cooling plate,

the first channel forming portion and the second channel forming portion are connected to each other.

7. The power conversion apparatus according to any one of claims 1 to 6, wherein,

the first cooling plate is provided with a first recess in which the refrigerant flows, the first recess being open toward the power supply substrate side,

a first heat-conducting plate is arranged between the first cooling plate and the power supply substrate, covers the first concave part and contacts with the power supply substrate,

the second cooling plate is provided with a second recess in which the refrigerant flows, the second recess opening toward the reactor side,

and a second heat conducting plate is arranged between the second cooling plate and the reactor, covers the second concave part and is contacted with the reactor.

8. The power conversion device of claim 7, wherein,

at least one of the first recess and the second recess has a bottom surface facing the opening side,

the bottom surface has an inclined surface that lightens the opening depth toward the downstream side of the refrigerant.

9. The power conversion apparatus according to any one of claims 1 to 8, wherein,

the first cooling plate is disposed between the power supply substrate and the power module, and the second cooling plate is disposed between the reactor and the capacitor module.

10. The power conversion apparatus according to any one of claims 1 to 9, wherein,

the first cooling plate and the second cooling plate are orthogonal to each other.

11. An electric motor apparatus, characterized in that,

having a power conversion device according to any one of claims 1 to 10.

12. A vehicle is characterized in that,

a motor apparatus as claimed in claim 11.