JP2009011106A - Connector unit, housing for rotary electric machine, and rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a novel connector unit that achieves cost reduction, to provide a housing for a rotary electric machine using the same, and to provide a rotary electric machine. <P>SOLUTION: A part of a connector unit 5 is connected to an opening part 60a of a motor housing body 60. The connector unit 5 is provided with externally-extending DC power supply terminals 23a2, 23b2, three-phase AC power supply terminals 23u2, 23v2, and 23w2 extending to the internal-space side of the motor housing, and a power conversion part 10 for executing conversion between a DC current and a three-phase AC current. In a state that the connector unit 5 is mounted to the motor housing body 60, the three-phase AC power supply terminals 23u2, 23v2, and 23w2 of the connector unit 5 and motor-side terminals 63u2, 63v2, and 63w2 are fixed by bolts or the like while being in contact with each other. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a novel connector unit, a housing for a rotating electrical machine including the connector unit, and the rotating electrical machine.

  FIG. 13 is a block circuit diagram showing an example of an electric system of a conventional hybrid vehicle. As shown in the figure, an engine 501, an engine radiator 502, an engine drive motor 503, and a three-phase AC power source for driving the motor 503 are generated in a vehicle body 500 of a conventional hybrid vehicle. A power generation unit 510 is provided. The power generation unit 510 includes an inverter 505 that supplies three-phase AC power for driving the motor 503, a battery 506 that supplies DC power to the inverter 505, and a converter 507 that converts the voltage of the DC power. Are arranged.

In the power generation unit 510 illustrated in FIG. 13, the power stored in the battery 506 is converted into a desired voltage by the converter 507, and DC power is supplied to the inverter 505. In the inverter 505, a power conversion unit incorporating a power device such as an IGBT is disposed, and a three-phase AC power source is generated from the DC power source in the power conversion unit. Thus, the three-phase AC power generated by the power generation unit 510 is sent to the motor 508 via the three-phase AC power line 508. Then, the motor 503 is rotated by the three-phase AC power source, and the engine 501 is driven. Converter 507, inverter 505, and battery 506 are housed in individual cases and are electrically connected by external wiring. For example, Patent Document 1 discloses a structure in which a power control unit and a motor are separated from each other. In the structure of this document, the battery 506 is disposed independently of the power generation unit 510.
JP 2006-74331 A

  However, in recent years, when further cost reduction is required, there is a problem in that the conventional configuration cannot sufficiently satisfy the requirement. Therefore, improvement for further cost reduction is demanded.

  The objective of this invention is providing the novel connector unit which can implement | achieve low cost, the housing of a rotary electric machine using the same, and a rotary electric machine.

The connector unit of the present invention integrally assembles a DC power supply terminal, a three-phase AC power supply terminal, and a power conversion unit for converting DC power and three-phase AC power, and a part thereof. It is configured to be connectable to a housing of a rotating electrical machine.
Here, the rotating electrical machine includes a motor and a generator.

As a result, the three-phase AC power supply terminals of the connector unit and the three-phase AC power supply terminals of the rotating electrical machine are very close to each other. Become. That is, by replacing the portion where the three-phase AC power supply wiring is used with the DC power supply wiring, it is possible to reduce cost and weight by reducing the amount of wiring used.
In addition, the connector unit of the present invention only needs to have a structure that can be connected to the housing of the rotating electrical machine. Therefore, the connector unit can be used by being connected to a member other than the housing of the rotating electrical machine. Has high usability.

In the connector unit, the power conversion portion is arranged on the inner space side of the housing rather than a part connected to the housing, so that the electrical connection between the three-phase AC power supply terminal and the rotating electrical machine side terminal is achieved. In addition to shortening the distance and reducing the component cost and weight by reducing the amount of wiring members used, the size can be reduced.
In particular, since the power conversion unit is disposed in the internal space of the housing of the rotating electrical machine, the power conversion unit can be accommodated in the housing of the rotating electrical machine in a compact manner, and further miniaturization can be achieved by effectively using the space. be able to.

  In general, the power conversion unit of the connector unit includes a wiring layer electrically connected to the DC power supply terminal and the three-phase AC power supply terminal, a power device electrically connected to the wiring layer, and a power The structure has a heat dissipation structure for releasing the heat of the device and a connection layer for fixing the first and second wirings to the heat dissipation structure.

  In that case, since the heat dissipation structure has a heat sink attached to the housing of the rotating electrical machine, it is possible to dissipate heat from the heat sink to the outside air through the housing, so that high heat dissipation performance can be exhibited. it can.

The structure to attach the DC power supply terminal is simplified by providing a through hole or side groove in the heat sink and having the DC power supply terminal reach the back side from the main surface side of the heat sink through the through hole or side groove. Will be.
Here, the main surface of the heat sink refers to the surface on which the power conversion unit is mounted among the surfaces of the heat sink, and the back surface refers to the surface facing the main surface.

  Furthermore, by providing a power device control circuit on the wiring layer with an insulating layer in between, the elements necessary for the power conversion unit can be stored compactly in the connector unit, and the space can be effectively used. be able to.

  In addition, since the first portion of the wiring layer is made of a metal plate common to the DC power supply terminal, the number of members can be reduced, thereby reducing the component cost. The same applies to the case where the second portion of the wiring layer is made of a metal plate common to the three-phase AC power supply terminal. In particular, since the three-phase AC power supply terminal extends to the internal space of the housing of the rotating electrical machine, the space in the internal space of the housing can be efficiently utilized.

  The connection layer is made of an adhesive, and the power device and the wiring layer are joined by the solder layer, so that the number of solder layers is reduced, so that the solder layer can be formed in a single process. Therefore, Pb-free solder having a relatively low melting point and high connection reliability can be used. Therefore, Pb-free can be achieved while ensuring connection reliability.

  A housing for a rotating electrical machine according to the present invention includes the connector unit and a housing body to which the connector unit is coupled. Thus, a power conversion unit is disposed and a high-functionality compact housing is provided. Is obtained.

  The housing of the rotating electrical machine may have a configuration in which the housing body has an opening, and the heat dissipation structure of the connector unit is attached to the edge of the opening, or the housing body has a heat dissipation structure of the connector unit. You may take the structure integrally molded with a part of body (for example, heat sink).

  The rotating electrical machine of the present invention includes a housing of the rotating electrical machine, and a rotor and a stator disposed in the housing. Thereby, the power conversion unit is disposed and has high functionality and is compact. A rotating electrical machine is obtained.

  In the above rotating electric machine, the three-phase AC power supply terminal of the stator is directly connected to the three-phase AC power supply terminal of the connector unit, thereby eliminating the need for the three-phase AC power supply wiring and further reducing the component cost. Can be reduced.

  According to the connector unit, the rotating electrical machine housing, or the rotating electrical machine of the present invention, it is possible to reduce the cost of components and reduce the weight.

(Embodiment 1)
-Electrical system configuration-
1 is a block diagram schematically showing a configuration of an electric system inside a vehicle body of a hybrid vehicle according to Embodiment 1. FIG. In the figure, members mainly related to the present invention are displayed. As shown in the figure, in a vehicle body 9 of a hybrid vehicle, an engine 1, an engine radiator 2, a motor 3 attached to the engine, and an inverter that generates a three-phase AC power source for driving the motor 3 , A battery 6 for supplying DC power to an inverter in the connector unit 5, and a converter 7 for converting the voltage of the DC power supply are arranged. Here, in the present embodiment, the connector unit 5 incorporating the inverter is coupled to the motor housing of the motor 3, and the connector unit 5 and the converter 7 are connected by the DC power supply wiring 8. Yes.

  In the present embodiment, electric power stored in the battery 6 is converted into a desired voltage by the converter 7, and DC power is supplied to the inverter in the connector unit 5. As will be described later, a power conversion unit incorporating a power device such as an IGBT is arranged in the inverter, and a three-phase AC power source is generated from the DC power source in the power conversion unit. Then, the motor 3 is rotated by the three-phase AC power source.

  In the present embodiment, the battery 6 and the converter 7 are disposed in the trunk, and the connector unit 5 is disposed in the engine room. Therefore, the connector unit 5 is connected from the converter 7 via a pair of DC power supply wires 8. DC power is supplied to the inverter inside. Therefore, the long three-phase AC power supply wiring as in the conventional configuration shown in FIG. 13 is not necessary, thereby reducing the cost of parts by reducing the amount of thick wiring used to supply large power. The weight can be reduced.

  FIG. 2 is an electric circuit diagram showing a circuit configuration from the battery 6 to the motor 3. In the figure, illustration of members such as a converter and a capacitor is omitted. As will be described later, the connector unit 5 is provided with a socket 28 to which the DC power supply wiring 8 is connected, and the connector unit 5 is provided with DC power supply metal wirings 23 a and 23 b extending from the socket 28. DC power is supplied.

  Although not shown in FIG. 1, the motor control unit 80 shown in FIG. 2 is arranged in the body 9 of the hybrid vehicle, and a control signal wiring 81 extends from the motor control unit 80. . On the other hand, the connector unit 5 is provided with a socket 29 to which a control signal wiring 81 is connected, and a control signal is supplied into the connector unit 5 through a control signal wiring 83 extending from the socket 29. .

  As shown in FIG. 2, in the connector unit 5, a power conversion unit 10 including a total of six switching circuits including IGBTs and diodes arranged in parallel is arranged. In the connector unit 5, a device driving circuit 16 for controlling the operation of each switching circuit in the connector unit is disposed. The device drive circuit 16 receives an input signal from the control signal wiring 83 extending from the socket 29, and outputs a control signal to each switching circuit via the control signal wiring 17.

  In the connector unit, each switching circuit is supplied with DC power via the DC power supply metal wires 23a and 23b, and the switching circuit is driven in accordance with the control signal of the device driving circuit 16, and the three-phase (U-phase) , V-phase, W-phase) power signals are generated, and the power signals are output to the motor 3 from the three-phase AC power supply metal wires 23u, 23v, 23w.

  The motor 3 is driven by three-phase (U-phase, V-phase, W-phase) AC, and the stator of the motor 3 is provided with bus bars 63u, 63v, 63w connected to the coil 3a. . Each bus bar 63u, 63v, 63w is connected to the three-phase AC power supply wirings 23u, 23v, 23w of the connector unit 5, respectively, and the motor 3 according to the three-phase AC power input to the bus bars 63u, 63v, 63w. The inner rotor rotates, and thereby the motor 3 is driven.

-Connector unit and motor housing connection structure-
FIG. 3 is a perspective view showing a part of the motor 3 in a broken state. FIG. 4 is a cross-sectional view of a part of the motor and the connector unit. However, the rotor is not shown in FIG. As shown in FIGS. 3 and 4, the motor housing body 60 is provided with a stator 61 and a rotor 65 that is rotationally driven in accordance with a current flowing through a coil of the stator 61. The stator 61 includes a core portion 62 formed by assembling a split core around which a coil is wound in a ring shape, and a ring portion 64 for fastening and fixing the split core assembled in a ring shape. And along the ring part 64 and the inner peripheral part of the core part 62, the three-phase bus-bars 63 and 66 connected to the coil wound around each division | segmentation core are arrange | positioned.
Each bus bar 63, 66 is connected to each coil wound around each divided core. However, in FIGS. 3 and 4, the connection structure between each bus bar 63, 66 and each coil is not shown. Yes. In FIG. 4, the bus bar 63 on the outer peripheral side is enlarged and displayed without the insulating coating layer.

  The motor housing body 60 is provided with an opening 60 a, and the connector unit 5 is fixed to the edge 60 b of the side tube 60 c surrounding the opening 60 a by the mounting screw 31. The outer peripheral bus bar 63 (63u, 63v, 63w) includes ring portions 63u1, 63v1, 63w1, and motor side terminals 63u2, 63v2, protruding from the ring portions 63u1, 63v1, 63w1 so as to be close to the opening 60a. 63w2.

  On the other hand, the connector unit 5 includes, as will be described later, DC power supply terminals 23a2 and 23b2 protruding toward the outside of the motor housing, and three-phase AC power supply terminals 23u2 and 23v2 protruding toward the inside of the motor housing. 23w2. In the present embodiment, when the connector unit 5 is mounted on the motor housing body 60, the three-phase AC power terminals 23u2, 23v2, 23w2 of the connector unit 5 and the motor side terminals 63u2, 63v2, 63w2 is fixed with a bolt or the like in a direct contact state.

-Connector unit structure-
Next, the structure of the connector unit 5 will be described. FIG. 5 is a perspective view of the connector unit 5 as viewed from the main surface side, and FIG. 6 is a perspective view of the connector unit 5 as viewed from the back surface side, and FIG. The reversed state is displayed.

  As shown in FIG. 5, each member of the connector unit 5 is mounted on the heat sink 21. A printed wiring board 33 on which a device drive circuit or the like is mounted is provided on the top, and all members except for external terminals are sealed with epoxy resin or the like (not shown) on the printed wiring board 33. Yes. The printed wiring board 33 is provided with a first opening 33a, a slit 33b, and a second opening 33c. An IGBT chip 11a on which an IGBT that is a power device is formed and a diode chip 11b on which a diode that is a power device is formed are disposed in the first opening 33c. A control signal wiring 83 is disposed in the second opening 33c. Also, three-phase AC power supply terminals 23u2, 23v2, and 23w2 protrude through the slit portion 33b.

  On the other hand, as shown in FIG. 6, when viewed from the back side of the heat sink 21, the heat sink 21 has a flat plate portion 21a and a fin portion formed with a large number of fins (not shown) protruding outward from the flat plate portion 21a. 21b and first and second openings 21c and 21d surrounded by sockets 28 and 29, respectively. Then, DC power supply terminals 23a2 and 23b2 are arranged in the first opening 21c, and a terminal part of the control signal wiring 83 is arranged in the second opening 21d.

Next, the structure of each member laminated on the heat sink of the connector unit 5 will be described. FIG. 7 is a perspective view showing through the layers other than the wiring layer on the heat sink 21. FIG. 8 is a perspective view showing the layers on the heat sink 21 separately.
As shown in FIGS. 7 and 8, a resin insulating layer 26, a metal wiring 23, and an insulating layer 35 are stacked between the heat sink 21 and the printed wiring board 33 in order from the bottom. The metal wiring 23 includes DC power supply metal wirings 23a and 23b for supplying DC power, and three-phase AC power supply metal wirings 23u, 23v and 23w for supplying three-phase AC power.

The DC power supply metal wires 23a and 23b have flat plate portions 23a1 and 23b1 extending in the lateral direction, and DC power supply terminals 23a2 and 23b2 which are bent from the flat plate portions 23a1 and 23b1 and extend downward in the drawing. Yes. That is, the DC power supply metal wires 23a and 23b have a substantially L-shaped cross-sectional shape.
Further, the three-phase AC power supply metal wires 23u, 23v, 23w are formed of flat plate portions 23u1, 23v1, 23w1 extending in the horizontal direction and three phases extending upward in the drawing by being bent from the flat plate portions 23u1, 23v1, 23w1. AC power supply terminals 23u2, 23v2, and 23w2 are provided. That is, the three-phase AC power supply metal wires 23u, 23v, and 23w have a substantially L-shaped cross-sectional shape.

Each of the flat plate portions 23a2, 23b2, 23u1, 23v1, and 23w1 constitutes the wiring layer of the present invention.
In the present embodiment, the flat plate portions 23a1 and 23b1 which are the first portions of the wiring layer are respectively a common metal plate with the DC power supply terminals 23a2 and 23b2 (in this embodiment, a Cu plate or a Cu alloy plate). ). Further, the flat plate portions 23u1, 23v1, 23w1 which are the second portions of the wiring layer are metal plates common to the three-phase AC power supply terminals 23u2, 23v2, 23w2, respectively (in this embodiment, a Cu plate or a Cu alloy plate). ).

The DC power supply terminals 23a2 and 23b2 extend through the first opening 26a of the resin insulating layer 26 and the first opening 21c of the flat plate 21a of the heat sink 21 into the socket 28 (see FIG. 6). . Further, the three-phase AC power supply terminals 23u2, 23v2, and 23w2 are inserted through the slit portion 35b of the insulating layer 35 and the slit portion 33b of the printed wiring board 33 and protrude above the printed wiring board 33 (see FIG. 5). ). Further, the end portion of the control signal wiring 83 is bent downward and extends into the socket 29 through the second opening portion 26 b of the resin insulating layer 26 and the second opening portion 21 d of the flat plate portion 21 a of the heat sink 21. ing.
In the present embodiment, the DC power supply terminals 23 a 2 and 23 b 2 extend from the main surface side to the back surface side through the first opening portion 21 c of the flat plate portion 21 a of the heat sink 21, but the first opening portion of the heat sink 21 Instead of 21c, a side groove in which the end surface of the flat plate portion 21a is cut out may be formed, and the DC power supply terminals 23a2, 23b2 may be inserted through the side groove and reach the back surface side.

-Structure of power converter-
9 is a cross-sectional view of the power conversion unit according to Embodiment 1 taken along line IX-IX shown in FIG.
The power conversion unit 10 includes a semiconductor chip 11 that displays the IGBT chip 11a and the diode chip 11b together, and a wiring layer (23a2, 23b2, 23u1) for electrically connecting a semiconductor element in the semiconductor chip 11 and an external member. , 23v1, 23w1). In the cross section shown in FIG. 9 of the wiring layer, the flat plate portions 23a1 and 23a2 of the DC power supply metal wires 23a and 23b and the flat plate portion 23w1 of the three-phase AC power supply metal wire 23w appear. In addition, a solder layer 14 including Pb-free solder that joins the respective flat plate portions 23a1, 23a2, 23w1 of the wiring layer and the semiconductor chip 11, and a heat sink 21 for releasing heat generated in the semiconductor chip 11 to the outside And an insulating resin layer 26 for fixing the flat plate portions 23a1, 23a2, and 23w1 of the wiring layer to the heat sink 21. Although not shown, the upper surface and the lower surface of the semiconductor chip 11 are respectively provided with an upper surface electrode and a back surface electrode connected to the active region of the IGBT and the diode. Are joined in a conductive state.

  Further, the upper surface electrode of the semiconductor chip 11 (the upper surface electrode of the IGBT chip or the upper surface electrode of the diode chip) and each flat plate portion of the wiring layer (23w1 and 23b1 in the cross section shown in FIG. 9) are the large current wiring 18. Are electrically connected. Further, in the semiconductor chip 11, the upper surface electrode of the IGBT chip and the upper surface electrode of the diode chip are also electrically connected by the large current wiring 18.

  The heat sink 21 includes a flat plate portion 21a and a fin portion 21b protruding from the back surface side of the flat plate portion 21a. The flat plate portion 21 a is attached to the edge portion 60 b of the side tube 60 c of the opening 60 a of the motor housing main body 60 by the mounting screw 31. The flat plate portion 21 a of the heat sink 21 functions as a support member that supports the wiring layer and the semiconductor chip 11. The heat sink 21 functions as a heat dissipation structure, functions as a housing for the connector unit 5, and also functions as a part of the motor housing. That is, the motor housing is constituted by the motor housing main body 60a and the heat sink 21.

  In the present embodiment, the heat sink 21 is naturally air-cooled, but a container 50 (see the broken line) surrounding the fin portion 21b is separately provided to forcibly circulate air or liquid for forced cooling. Good. However, the fin part 21b is not necessarily required, and other heat radiating members may be provided instead of the fin part 21b.

  Further, a socket 28 is provided in the first opening 21 c of the heat sink 21, and a DC power supply terminal 23 a 2 bent from the flat plate portion 23 a 1 of the DC power supply metal wiring 23 a extends to the socket 28. Although not appearing in the cross section shown in FIG. 9, a DC power supply terminal 23b2 bent substantially at a right angle from the flat plate portion 23b1 of one of the DC power supply metal wires 23b also extends to the socket 28 (FIGS. 7 and 8). reference). That is, each DC power supply terminal 23 a 2, 23 b 2 extends to the external space of the motor housing body 60.

  Further, in a cross section other than the cross section shown in FIG. 9, the three-phase AC power supply terminal 23 w 2 bent substantially at a right angle from the flat plate portion 23 w 1 of the three-phase AC power supply metal wiring 23 w extends into the internal space of the motor housing body 60. Yes. The three-phase AC power supply terminal 23w2 is fixed by the attachment member 37 in a state of being in direct contact with the motor side terminal 63w2. Although not shown in FIG. 9, the three-phase AC power supply terminals 23u2 and 23v2 bent substantially at right angles from the flat plate portions 23u1 and 23v1 of the other three-phase AC power supply metal wires 23u and 23v have the same configuration. ing.

  Further, a printed wiring board 33 is laminated above the wiring layer via an insulating layer 35, and the device driving circuit 16 is disposed on the printed wiring board 33. A signal wiring 17 for supplying a control signal is electrically connected between a signal wiring (not shown) extending on the printed wiring board 33 and a control electrode (not shown) of the semiconductor chip 11. It is connected to the.

  Although not shown in FIG. 9, the semiconductor chip 11, the control signal wiring 17, the high current wiring 18, the printed wiring board 33, the insulating layer 35, the wiring layer, the solder layer 14, Members such as the insulating resin layer 26 are made of epoxy resin or the like except for the terminal portions of the DC power supply terminals 23a2, 23b2, the three-phase AC power supply terminals 23u2, 23v2, 23w2, the motor side terminal 63w2, and the control signal wiring 83. It is sealed with resin.

In the present embodiment, the diameter of the outer peripheral portion of the motor housing body 60 is, for example, about 350 mm, the size of the opening 60 a is, for example, 100 mm × 150 mm, and the planar size of the flat plate portion 21 a of the heat sink 21 is, for example, 100 mm. The height dimension of the entire connector unit 5 is, for example, about 50 mm.
Therefore, it is possible to realize a compact connector unit 5 that is reduced in size as compared with the conventional structure in which the power conversion unit and the external terminal are combined.

-Assembly procedure of connector unit-
The connector unit 5 of the present embodiment can be assembled separately by the following procedure before being attached to the motor housing body 60. The assembly procedure will be described with reference to FIGS.
First, Pb-free solder is discharged or printed on the metal wiring 23, and the semiconductor chip 11 is mounted on the Pb-free solder. The semiconductor chip 11 is formed with an IGBT or a diode that functions as a power device. Further, the power conversion unit is put into a reflow furnace, and the solder layer 14 for joining the semiconductor chip 11 and the metal wiring 23 is formed. The atmosphere of the reflow furnace at this time is an inert gas atmosphere or a reducing atmosphere, and the maximum temperature in the furnace is 260 ° C. Thereafter, flux cleaning is performed to remove the flux residue.

Next, an insulating epoxy resin having a high thermal conductivity is applied to the upper surface of the flat plate portion 21a of the heat sink 21 formed by die casting to form the insulating resin layer 26. Next, the metal wiring 23 patterned in a predetermined shape is mounted on the insulating resin layer 26, and the metal wiring 23 is fixed to the upper surface of the flat plate portion 21 of the heat sink 21 by the insulating resin layer 26.
It is possible to form the heat sink 21 by extrusion molding. In this case, the openings 21 c and 21 d can be processed after molding, and sockets 28 and 29 formed separately can be attached to the heat sink 21.

  Next, an insulating adhesive is applied on the flat plate portion of the metal wiring 23 to form the insulating layer 35, and the printed wiring board 33 is placed thereon. At this time, the semiconductor chip 11 is exposed to the first opening 33a, the three-phase AC power supply terminals 23u2, 23v2, and 23w2 are inserted through the slit 33b, and the terminal of the control signal wiring 83 is connected to the second opening 33c. Insert.

  Thereafter, wire bonding using an Al wire having a relatively large diameter (for example, 400 μm diameter) is performed. Then, a large current wiring 18 that connects the upper surface electrodes of the semiconductor chip 11 or between the upper surface electrode and the metal wiring 23 is formed. Thereafter, wire bonding using a small diameter (for example, 125 μm diameter) Al wire is performed to form a signal wiring 17 that connects between a control electrode (not shown) of the semiconductor chip 11 and a wiring on the printed wiring board 33. To do.

Next, the members such as the semiconductor chip 11, the signal wiring 17, the large current wiring 18, the metal wiring 23, the solder layer 14, and the insulating resin layer 26 provided on the main surface of the heat sink 21 by potting are connected to the terminals. Sealing with the part exposed.
After the connector unit 5 is formed separately from the motor housing body 60 by the above steps, the connector unit 5 is attached to the motor housing body 60.

  In the present embodiment, sintered aluminum (sintered Al) is used as the material of the heat sink 21. However, it is not limited to this. For example, other metals such as Al, Al alloy, Cu, and Cu alloy, ceramics such as AlN, SiN, BN, and SiC, or composite materials such as Al—SiC, Cu—W, and Cu—Mo may be used. .

  In the present embodiment, Cu or Cu alloy is used as the material of the metal wiring 23 (23a, 23b, 23u, 23v, 23w), but is not limited thereto. For example, a composite material such as Al, Al alloy, Al—SiC, Cu—W, or Cu—Mo may be used.

  In the present embodiment, wiring layers (each flat plate portion 23a1, 23b1, 23u1, 23v1, 23w1) and terminals to external devices (DC power supply terminals 23a2, 23b2 and three-phase AC power supply terminals 23u2, 23v2, 23w2) Are configured by a single metal plate (in this embodiment, a Cu plate or a Cu metal plate), but a wiring layer and a terminal may be provided separately and connected by an Al wire or the like. Good.

  As described above, the power conversion unit 10 of the present embodiment includes the solder layer 14 made of Pb-free solder and the insulating resin layer 26. In general, Pb-free solder includes the following. For example, Sn (liquid phase point 232 ° C.), Sn-3.5% Ag (liquid phase point 221 ° C.), Sn-3.0% Ag (liquid phase point 222 ° C.), Sn-3.5% Ag−0.55% Cu (liquid phase point) 220 ° C.), Sn-3.0% Ag-0.5% Cu (liquid phase point 220 ° C.), Sn-1.5% Ag-0.85% Cu-2.0 Bi (liquid phase point 223 ° C.), Sn-2.5% Ag-0.5% Cu -1.0Bi (liquid phase point 219 ° C), Sn-5.8Bi (liquid phase point 138 ° C), Sn-0.55% Cu (liquid phase point 226 ° C), Sn-0.55% Cu-others (liquid phase point 226 ° C) , Sn-0.55% Cu-0.3% Ag (liquid phase point 226 ° C), Sn-5.0% Cu (liquid phase point 358 ° C), Sn-3.0% Cu-0.3% Ag (liquid phase point 312 ° C), Sn- 3.5% Ag-0.5% Bi-3.0In (liquid phase point 216 ° C), Sn-3.5% Ag-0.5% Bi-4.0In (liquid phase point 211 ° C), Sn-3.5% Ag-0.5% Bi-8.0In (Liquid phase point 208 ° C), Sn-8.0% Zn 3.0% Bi (liquidus point 197 ° C.), and the like. In this embodiment, a low-melting point Pb-free solder having a liquidus point of 250 ° C. or lower, for example, Sn-3.0% Ag-0.5% Cu (liquidus point 220 ° C.) is used. It is not a thing. However, high melting point Pb-free solder such as Sn-5.0% Cu (liquid phase point 358 ° C), Sn-3.0% Cu-0.3% Ag (liquid phase point 312 ° C) (liquid phase point exceeding 250 ° C) Shall be excluded.

  In the present embodiment, an epoxy resin containing a metal or ceramic filler is used for the insulating resin layer 26. Although the usable temperature of the epoxy resin varies depending on the type, it is easy to select a temperature exceeding 250 ° C. In this embodiment, a temperature higher than the liquid phase point of Pb-free solder is used. Therefore, it becomes possible to perform a reflow process of Pb-free solder after the insulating resin layer 26 is formed in the assembly process of the power conversion unit described later. For example, an epoxy resin filled with alumina, silica, aluminum, aluminum nitride, or the like can be used, and the thermal conductivity is preferably 3.0 (W / m · K) or more, and 5.0 ( W / m · K) or more is more preferable.

  The thickness of the insulating resin layer 26 is preferably 0.4 mm or less, and more preferably 0.2 mm or less. The thermal resistance of the insulating resin layer 26 is determined depending on the thermal conductivity and thickness, but the thermal resistance decreases as the thickness decreases. Therefore, heat dissipation performance will become high because thickness is 0.4 mm or less.

  According to the present embodiment, a power converter that functions as an inverter for converting DC power into three-phase AC power between DC power terminals 23a2, 23b2 and three-phase AC power terminals 23u2, 23v2, 23w2. 10 is provided, and a part of the connector unit 5 (in this embodiment, the heat sink 21 which is a heat dissipation structure) is connected to the motor housing main body 60, so that a DC power source is generated. Between the battery 6 and the converter 7 and the power conversion unit 10, it is only necessary to provide a DC power supply wiring instead of the three-phase AC power supply wiring. Reduction and weight reduction can be achieved.

As can be seen from the above assembling method, the connector unit 5 of the present embodiment can be assembled separately from the motor housing main body 60. Therefore, not only the motor housing main body 60 but also DC power—three-phase AC power. It can be attached to a device that performs this conversion and other members, and has high utility as a versatile connector unit.
In addition, since the power conversion unit 10 is disposed in the internal space of the motor housing, the internal space of the motor housing can be used effectively, and eventually the members inside the vehicle can be reduced in size.

  In particular, the heat sink 21 that is a heat dissipation structure is attached in contact with the motor housing body 60 (see FIG. 9), and the heat sink 21 is used as a part of the motor housing. In addition, the heat dissipation performance is improved through the motor housing body 60. That is, the heat generated in the semiconductor chip 11 is conducted to the housing body 60 via the back electrode-solder layer 14 -resin insulating layer 26 -heat sink 21 and is radiated from the surface of the housing body 60.

  Moreover, since the printed wiring board 33 which mounts the device drive circuit 16 which is a control circuit for controlling the operation | movement of a power device is integrated in the power converter 10, compactization of the member inside a vehicle can be achieved. .

  In addition, the flat plate portions 23a1 and 23b1 of the DC power supply wires 23a and 23b and the DC power supply terminals 23a2 and 23b2 in the wiring layer are formed of a common metal plate, thereby reducing the manufacturing cost and the connector unit 5. Can be reduced in size.

  In the wiring layer, flat plate portions 23u1, 23v1, 23w1 of three-phase AC power supply metal wires 23u, 23v, 23w and three-phase AC power supply terminals 23u2, 23v2, 23w2 are formed of a common metal plate. As a result, it is possible to reduce the manufacturing cost and the size of the connector unit 5.

  In the present embodiment, instead of the conventionally used two solder layers, one solder layer 14 and an insulating resin layer 26 made of a resin adhesive are used. Therefore, a low melting point Pb-free solder is used. It is not necessary to use high melting point Pb-free solder, and only low melting point Pb-free solder is required. Currently, Pb-free solder having a relatively high Cu composition ratio (for example, Sn-5.0% Cu, Sn-3.0% Cu-0.3% Ag having a liquidus point of 300 ° C. or higher) has been developed as a Pb-free solder. It is difficult to obtain a high melting point Pb-free solder having reliable connection reliability. On the other hand, as the low melting point Pb-free solder, for example, a solder having high connection reliability such as Sn-3.0% Ag-0.5% Cu (JEITA recommended alloy) having a liquidus point of 220 ° C. has been obtained. As the resin adhesive, an epoxy resin having a usable temperature exceeding 250 ° C. can easily be obtained that can withstand a higher temperature than the liquid phase point of the low melting point Pb-free solder. Therefore, according to the present embodiment, the solder layer 14 can be made Pb-free and Pb-free can be achieved while ensuring connection reliability.

(Embodiment 2)
FIG. 10 is a cross-sectional view of the power conversion unit according to the second embodiment, taken along the line IX-IX shown in FIG. In the figure, members having the same configurations as those of the first embodiment are denoted by the same reference numerals as those of the first embodiment, and description thereof is omitted.
As shown in the figure, in the present embodiment, the heat sink 21 is integrally formed with the motor housing body 60 and functions as a part of the motor housing.

  According to the present embodiment, since the heat sink 21 that is a heat dissipation structure is formed integrally with the motor housing body 60, the thermal conductivity between the heat sink 21 and the motor housing 60 can be further improved. Higher heat dissipation performance than that of Mode 1 can be exhibited.

(Embodiment 3)
FIG. 11 is a cross-sectional view of the power conversion unit according to the third embodiment, taken along the line IX-IX shown in FIG. In the figure, members having the same configurations as those of the first embodiment are denoted by the same reference numerals as those of the first embodiment, and description thereof is omitted.
As shown in the figure, in the present embodiment, a side portion 21f surrounding the flat portion 21a of the heat sink 21 is provided, and the side portion 21f is attached to the outer peripheral surface of the motor housing main body 60a to convert power. The part 10 is located outside the motor housing body 60. The three-phase AC power supply terminal 23w2 (and 23u2, 23v2) extends through the opening 60b formed in the motor housing body 60 to the internal space of the motor housing.

  In the present embodiment, the power conversion unit 10 is not located in the internal space of the motor housing, but is disposed closer to the internal space of the motor housing than the heat sink 21, so that the three-phase AC power terminals 23u2, 23v2 , 23w2 and the inner space of the motor housing become shorter. Therefore, in addition to reducing the component cost and weight by reducing the amount of wiring members used, it is possible to reduce the size. Further, if the motor housing body 60a is disposed in an empty space, it is possible to reduce the size of members inside the vehicle by effectively using the space.

  In the present embodiment, the DC power supply terminals 23a2 and 23b2 are not bent in an L shape, but may be flat plates as a whole. In that case, through holes and terminal connection sockets are formed on the side of the heat sink 21, and the DC power supply terminals 23 a 2 and 23 b 2 extend substantially parallel to the flat plate portion 21 a of the heat sink 21, What is necessary is just to insert in the through-hole of a part and to reach a socket. Also in this case, the DC power supply terminals 23a2 and 23b2 reach the back surface side (external space side) of the side portion from the main surface side (internal space side) of the side portion of the heat sink 21.

(Modification of three-phase AC power terminal)
In each of the above embodiments, the three-phase AC power supply terminals 23u2, 23v2, and 23w2 are provided in a flat plate shape, but a structure for providing elasticity can be employed.

  12A to 12D are cross-sectional views showing first to fourth modifications of the three-phase AC power supply terminal. The first modification shown in FIG. 12A has a structure in which a partial cross-sectional shape of the three-phase AC power supply terminals 23u2, 23v2, and 23w2 is formed in a curved shape. The second modification shown in FIG. 12B has a structure in which a partial cross-sectional shape of the three-phase AC power supply terminals 23u2, 23v2, and 23w2 is formed in a semicircular loop shape. The third modification shown in FIG. 12 (c) has a structure in which a partial cross-sectional shape of the three-phase AC power supply terminals 23u2, 23v2, 23w2 is formed in a bellows shape. In the fourth modification shown in FIG. 12 (d), the tips of the three-phase AC power terminals 23u2, 23v2, 23w2 are bent, and the tips of the motor side terminals 63u2, 63v2, 63w2 are also bent to connect the tips. It has a structure.

  By giving elasticity to the three-phase AC power terminals 23u2, 23v2, 23w2 as in these modified examples, vibrations of the motor, the vehicle body, etc. are transmitted to the power converter 10 via the three-phase AC power terminals 23u2, 23v2, 23w2. It is possible to suppress adverse effects due to this and loosening of coupling between the three-phase AC power supply terminals 23u2, 23v2, 23w2 and the motor side terminals 63u2, 63v2, 63w2.

(Other embodiments)
In the above embodiment, a structure in which a part of the connector unit is connected to the motor housing has been disclosed. Can be applied. That is, the present invention can also be applied to motor and generator housings.

  The semiconductor element disposed in the power conversion unit of the present invention may be a power device using a wide band gap semiconductor (SiC, GaN, etc.) or a power device using Si.

  In the said embodiment, although the power conversion part was an inverter which combined IGBT and a diode, the power conversion part of this invention may be an inverter using MOSFET.

  In the said embodiment, although the heat radiating structure was comprised only by the heat sink 21, the heat radiating structure may have a heat sink and another member. A member other than the heat sink or a member other than the heat dissipation structure may be coupled to the housing of the rotating electrical machine.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  The connector unit, the rotating electrical machine housing, and the rotating electrical machine according to the present invention can be used for a motor such as a hybrid vehicle, an electric vehicle, a compressor of a refrigeration apparatus, or a generator.

1 is a block diagram schematically showing a configuration of an electric system inside a vehicle body of a hybrid vehicle according to Embodiment 1. FIG. FIG. 3 is an electric circuit diagram showing a circuit configuration from the battery to the motor in the first embodiment. It is a perspective view which fractures | ruptures and shows a part of motor. It is sectional drawing of a part of motor and a connector unit. It is the perspective view which looked at the connector unit from the main surface side. It is the perspective view which looked at the connector unit from the back side. It is a perspective view which sees and shows each layer other than the wiring layer on a heat sink. It is a perspective view which isolate | separates and displays each layer on a heat sink. It is sectional drawing in the IX-IX line shown in FIG. 7 of the power converter which concerns on Embodiment 1. FIG. FIG. 8 is a cross-sectional view of the power conversion unit according to the second embodiment, taken along the line IX-IX shown in FIG. 7. FIG. 9 is a cross-sectional view of a power conversion unit according to Embodiment 3 in a cross-section corresponding to the line IX-IX shown in FIG. 7. (A)-(d) is sectional drawing which shows the 1st-4th modification of the terminal for three-phase alternating current power supplies. It is a block circuit diagram which shows the example of the electric system of the conventional hybrid vehicle.

Explanation of symbols

1 Engine 2 Radiator 3 Motor 5 Connector Unit 6 Battery 7 Converter 8 DC Power Supply Wiring 8
DESCRIPTION OF SYMBOLS 10 Power conversion part 11a IGBT chip 11b Diode chip 14 Solder layer 16 Device drive circuit 17 Control signal wiring 18 High current wiring 21 Heat sink 21a Flat plate part 21b Fin part 21c 1st opening part 21d 2nd opening part 23a, 23b DC power supply Metal wiring 23a1, 23b1 flat plate portion 23a2, 23b2 DC power supply terminal 23u, 23v, 23w three-phase AC power supply metal wiring 23u1, 23v1, 23w1 flat plate portion 23u2, 23v2, 23w2 three-phase AC power supply terminal 26 insulating resin layer 26a First opening 26b Second opening 28 Socket 29 Socket 31 Mounting screw 33 Printed wiring board 33a First opening 33b Slit 33c Second opening 35 Insulating layer 35a First opening 35b Slit 35c Second opening 37 Mounting member 50 Container 60 Motor how Ring body 60a opening 60b edge 60c side tube 63u, 63v, 63w busbar 63u1,63v1,63w1 ring portion 63u2,63v2,63w2 motor side terminal
80 Motor control unit 81 Control signal wiring 83 Control signal wiring

Claims (18)

A DC power supply terminal;
A three-phase AC power supply terminal;
A power conversion unit disposed between the DC power supply terminal and the three-phase AC power supply terminal, for performing power conversion between the DC power and the three-phase AC power;
It is constructed by assembling integrally,
A connector unit that is partly connectable to the housing of a rotating electrical machine. The connector unit according to claim 1,
The power conversion unit is a connector unit that is disposed closer to the inner space of the housing of the rotating electrical machine than the part. The connector unit according to claim 1 or 2,
The power conversion unit is a connector unit disposed in an internal space of the housing of the rotating electrical machine. In the connector unit in any one of Claims 1-3,
The power converter is
A wiring layer electrically connected to the DC power supply terminal and the three-phase AC power supply terminal;
A power device electrically connected to the wiring layer;
A heat dissipation structure for releasing heat of the power device;
A connection layer for fixing the first and second wirings to the heat dissipation structure;
Having a connector unit. The connector unit according to claim 4,
The part is a connector unit, which is the heat dissipation structure. The connector unit according to claim 5, wherein
The heat dissipation structure has a heat sink attached to a housing of the rotating electrical machine. The connector unit according to claim 6,
The heat sink is provided with a through hole or a side groove,
The DC power supply terminal is a connector unit that reaches from the main surface side to the back surface side of the heat sink via the through hole or side groove. In the connector unit in any one of Claims 4-7,
A connector unit further comprising a control circuit for the power device, which is disposed on the wiring layer with an insulating layer interposed therebetween. In the connector unit according to any one of claims 4 to 8,
A connector unit, wherein the first portion of the wiring layer is formed of a metal plate common to the DC power supply terminal. In the connector unit according to any one of claims 4 to 9,
The second portion of the wiring layer is a connector unit configured by a metal plate common to the three-phase AC power supply terminal. The connector unit according to claim 10, wherein
The three-phase AC power supply terminal extends to the internal space of the housing of the rotating electrical machine. In the connector unit in any one of Claims 4-11,
The connection layer is made of an adhesive,
The connector unit in which the power device and the wiring layer are joined by a solder layer. In the connector unit according to any one of claims 1 to 12,
The three-phase AC power supply terminal is a connector unit having an elastic structure. The connector unit according to any one of claims 1 to 13,
A housing body to which the connector unit is coupled;
A rotating electrical machine housing. The housing of the rotating electric machine according to claim 14,
The housing body has an opening,
The heat dissipating structure is a housing of a rotating electrical machine attached to an edge of the opening. The housing of the rotating electric machine according to claim 14,
The housing of the rotating electrical machine, wherein the housing body is integrally formed with a part of the heat dissipation structure of the connector unit. A housing for a rotating electrical machine according to any one of claims 14 to 16,
A rotor and a stator disposed in the housing;
Rotating electric machine equipped with. The rotating electrical machine according to claim 17,
The three-phase AC power supply terminal of the stator is a rotating electrical machine directly connected to the three-phase AC power supply terminal of the connector unit.

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