JP2023131686A - Power conversion device - Google Patents

Abstract

To provide a power conversion device in which the versatility of a bus bar is enhanced.SOLUTION: A power conversion device includes a plurality of switch modules that are arranged in a y direction, and a third P bus bar 133 and a second N bus bar 142 that are connected to collector terminals 295 and emitter terminals 296 of the switch modules. The power conversion device includes a smoothing capacitor 310 that is connected to the bus bars.SELECTED DRAWING: Figure 1

Description

The disclosure described in this specification relates to a power conversion device.

As shown in Patent Document 1, a power conversion device is known in which a plurality of semiconductor modules are connected to a capacitor element via a bus bar.

JP2018-98913A

The bus bar described in Patent Document 1 includes an electrode portion connected to a capacitor element and a base portion connected to the electrode portion. A plurality of holes are formed in the base. Branches extend from the edge of this hole. The tip of the terminal of the semiconductor module passes through this hole. The tip of this terminal is connected to the branch.

By the way, the same number of holes and branch parts as the total number of terminals included in the plurality of semiconductor modules are formed in the base of the bus bar. Therefore, as the number of semiconductor modules increases, the shape of the bus bar must be changed to increase the number of holes and branches. As described above, the bus bar described in Patent Document 1 has a problem of low versatility with respect to an increase in the number of terminals of a semiconductor module.

An object of the present disclosure is to provide a power conversion device in which the versatility of the bus bar is improved.

A power conversion device according to one aspect of the present disclosure includes a plurality of switch modules (271 to 278) arranged in an arrangement direction,
bus bars (133, 142) connected to connection terminals (295, 296) of each of the plurality of switch modules;
A capacitor (310) connected to each of the plurality of switch modules via a bus bar,
The bus bar has more connection parts than connection terminals,
All of the plurality of connection terminals are connected to some of the plurality of connection parts.

According to this, the versatility of the bus bar is improved.

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

1 is a circuit diagram showing an in-vehicle system. FIG. 3 is a top view of the power conversion device. It is a front view of a power conversion device. It is a right view of a power conversion device. FIG. 3 is a rear view of the power conversion device. FIG. 3 is a left view of the power conversion device. FIG. 3 is a bottom view of the power conversion device. FIG. 3 is an exploded front view of the power conversion device. FIG. 3 is an exploded right side view of the power conversion device. FIG. 3 is an exploded rear view of the power conversion device. This is the disassembled left side of the power converter. FIG. 3 is a bottom view of the lower module. FIG. 3 is a top view of the upper module. FIG. 3 is a top view of the upper wiring board. FIG. 3 is a top view of the signal connector. FIG. 3 is a top view showing a state in which the control board is provided in the upper housing. FIG. 3 is a top view of the switch module. FIG. 3 is a front view of the switch module. FIG. 3 is a right view of the switch module. FIG. 3 is a rear view of the switch module. FIG. 3 is a left view of the switch module. FIG. 3 is a bottom view of the switch module. It is a top view of a cooler. It is a top view of a cooler. It is a front view of a cooler. FIG. 3 is a rear view of the cooler. FIG. 3 is a perspective view of a capacitor module. FIG. 3 is a front view of the capacitor module. FIG. 3 is a top view of the bus bar module. It is a front view of a bus bar module. FIG. 3 is a right view of the bus bar module. FIG. 3 is a rear view of the bus bar module. FIG. 3 is a left view of the bus bar module. FIG. 3 is a bottom view of the bus bar module.

Hereinafter, a plurality of embodiments for carrying out the present disclosure will be described with reference to the drawings. In each form, parts corresponding to matters explained in the preceding form may be given the same reference numerals and redundant explanation may be omitted. When only a part of the configuration is described in each form, the other forms previously described can be applied to other parts of the structure.

It is possible to combine parts that are specifically indicated as possible in each embodiment. In addition, it is also possible to partially combine embodiments, embodiments and modifications, and modifications, even if it is not explicitly stated that combinations are possible, as long as there is no particular problem with the combination. be.

(First embodiment)
<In-vehicle system>
First, an in-vehicle system 100 provided with a power conversion device 30 will be described based on FIG. This in-vehicle system 100 constitutes a system for electric vehicles.

The in-vehicle system 100 includes a battery 10, a system switch 20, a power converter 30, and a motor 40. In the drawings, the battery 10 is indicated as BATT.

The in-vehicle system 100 includes a power wire harness 110, a power wire harness 120, a P bus bar 130, an N bus bar 140, and a phase bus bar 150 as components for electrically connecting various electrical components included in the above components. It is included.

Various electrical components included in each of the battery 10, system switch 20, and power conversion device 30 are electrically connected via a power supply wire harness 110, a P bus bar 130, and an N bus bar 140. Various electrical components included in the power conversion device 30 and the motor 40 are electrically connected via a phase bus bar 150 and a power wire harness 120.

Furthermore, the in-vehicle system 100 includes multiple ECUs. These plurality of ECUs mutually transmit and receive electrical signals via bus wiring. Multiple ECUs work together to control the electric vehicle. Power running and regeneration of the motor 40 are controlled according to the SOC of the battery 10 under the control of a plurality of ECUs. SOC is an abbreviation for state of charge. ECU is an abbreviation for electronic control unit.

The battery 10 includes a plurality of battery stacks electrically connected in series or in parallel. Each of the plurality of battery stacks has a plurality of secondary batteries electrically connected in series. As the secondary battery, a lithium ion secondary battery, a nickel hydride secondary battery, an organic radical battery, etc. can be employed. Note that the battery 10 may have only one battery stack.

The system switch 20 has a first SMR 21 and a second SMR 22. SMR is an abbreviation for system main relay. Each of the first SMR 21 and the second SMR 22 is a mechanical switch. The mechanical switch is a normally closed switch that becomes energized when no control signal is input.

The first SMR 21 and the second SMR 22 are provided in the power supply wire harness 110. The first SMR 21 is connected to the P bus bar 130. The second SMR 22 is connected to the N bus bar 140. The first SMR 21 and the second SMR 22 control energization and interruption of power between the battery 10 and the power conversion device 30.

Although not shown, a precharge circuit is connected in parallel to the second SMR 22. The precharge circuit includes a charging switch and a charging resistor connected in series. The charging switch is controlled to be energized when charging the capacitive element included in the in-vehicle system 100. At this time, the second SMR 22 is controlled to be in the cut-off state, and the first SMR 21 is controlled to be in the energized state. Through such control, the DC power of the battery 10 is supplied to the above-mentioned capacitive element via the charging resistor.

Note that a precharge circuit may be connected in parallel to the first SMR 21. When controlling the charging switch to be energized with this configuration, the first SMR 21 is controlled to be in the cut-off state and the second SMR 22 is controlled to be energized.

Power conversion device 30 performs power conversion between battery 10 and motor 40. Power conversion device 30 and motor 40 are electrically connected via power wire harness 120. The power conversion device 30 will be explained in detail later.

The motor 40 has a first MG41 and a second MG42. MG is an abbreviation for motor generator. The first MG 41 has a first output shaft, a first rotor provided on the first output shaft, and stator coils of U1 phase, V1 phase, and W1 phase that are arranged to face the first rotor. The second MG 42 includes a second output shaft, a second rotor provided on the second output shaft, and U2-phase, V2-phase, and W2-phase stator coils arranged to face the second rotor.

The output shafts of the first MG 41 and the second MG 42 are connected to an axle 44 of the electric vehicle via a gearbox 43. The rotational energy of the first MG 41 and the second MG 42 is transmitted to the running wheels of the electric vehicle via the gearbox 43 and the axle 44. Conversely, the rotational energy of the running wheels is transmitted to the first MG 41 and the second MG 42 via the axle 44 and gearbox 43.

The first MG 41 and the second MG 42 are powered by AC power supplied from the power conversion device 30, respectively. This provides propulsion to the running wheels. Further, the first MG 41 and the second MG 42 are regenerated by rotational energy transmitted from the running wheels. The AC power generated by this regeneration is converted to DC power by the power conversion device 30 and is stepped down. This DC power is supplied to the battery 10. This DC power is also supplied to various electrical loads mounted on the electric vehicle.

Note that it is also possible to adopt a configuration in which the battery 10 includes a fuel cell. In this case, the AC power generated by regeneration is not supplied to the battery 10. This AC power is not used to charge the battery 10.

<Power conversion circuit>
Next, the power conversion circuit 200 included in the power conversion device 30 will be explained. As shown in FIG. 1, power conversion circuit 200 includes a converter 210 and an inverter 220.

Converter 210 is connected to battery 10 via power supply wire harness 110, P bus bar 130, and N bus bar 140. Further, converter 210 is connected to inverter 220 via P bus bar 130 and N bus bar 140. Inverter 220 is connected to the stator coil of motor 40 via phase bus bar 150 and power wire harness 120.

The phase bus bar 150 includes a U1 phase bus bar 151 to a W1 phase bus bar 153, and a U2 phase bus bar 154 to a W2 phase bus bar 156. The U1 phase bus bar 151 to W1 phase bus bar 153 are individually connected to the U1 phase, V1 phase, and W1 phase stator coils of the first MG 41. The U2 phase bus bar 154 to the W2 phase bus bar 156 are individually connected to the U2 phase, V2 phase, and W2 phase stator coils of the second MG 42.

Converter 210 boosts the DC power of battery 10 to a voltage level suitable for powering motor 40. Inverter 220 converts this DC power into AC power. This AC power is supplied to the first MG 41 and the second MG 42.

Inverter 220 converts AC power generated by power generation (regeneration) of first MG 41 and second MG 42 into DC power. Converter 210 steps down this DC power to a voltage level suitable for charging battery 10. This step-down DC power is supplied to the battery 10 and various electrical loads.

The power conversion circuit 200 includes a physical quantity sensor 230 and a control board 240 in addition to a converter 210 and an inverter 220.

Physical quantity sensor 230 detects physical quantities of converter 210 and inverter 220. Examples of physical quantities detected by the physical quantity sensor 230 include temperature, current, and voltage. The physical quantity sensor 230 is provided in various electrical components included in the converter 210 and inverter 220, and in the various bus bars described above.

Specifically, the physical quantity sensor 230 includes a voltage sensor 231, a temperature sensor 232, and a current sensor 233. Voltage sensor 231 is provided at P bus bar 130 and N bus bar 140. The temperature sensor 232 is provided in a switch module 270, which will be described later. Current sensor 233 is provided on phase bus bar 150 . Note that the current sensor 233 may also be provided on the P bus bar 130 or the N bus bar 140. In the drawings, these various sensors are shown as blocks.

The control board 240 has a gate driver 241. In the drawings, the gate driver 241 is expressed as GD. In this embodiment, the control board 240 includes one EVECU 242 of a plurality of ECUs.

The control board 240 is electrically connected to another ECU different from the EVECU 242. The control board 240 is electrically connected to the physical quantity sensor 230. Additionally, control board 240 is electrically connected to switches included in converter 210 and inverter 220. Control board 240 controls the switches included in converter 210 and inverter 220 to be in an energized state and an energized state based on signals input from physical quantity sensor 230 and other ECUs.

Note that it is also possible to employ a configuration in which the gate driver 241 and the EVECU 242 are included in separate substrates. In such a configuration, the board including the gate driver 241 and the board including the EVECU 242 are electrically connected, for example, via a wire harness.

<Converter>
Converter 210 includes a filter capacitor 250 and a reactor 260. Converter 210 also includes a switch module 270 as a common component with inverter 220. Switch module 270 includes an A-phase switch module 271 and a B-phase switch module 272 included in converter 210.

As shown in FIG. 1, the P bus bar 130 includes a first P bus bar 131, a second P bus bar 132, and a third P bus bar 133. The N bus bar 140 includes a first N bus bar 141 and a second N bus bar 142.

The first P bus bar 131 is connected to one end of the reactor 260. The second P bus bar 132 is connected to the other end of the reactor 260.

Filter capacitor 250 is connected to first P bus bar 131 and first N bus bar 141 . A second N bus bar 142 is connected to the first N bus bar 141 .

The A-phase switch module 271 and the B-phase switch module 272 are connected to the second P bus bar 132, the third P bus bar 133, and the second N bus bar 142, respectively. The A-phase switch module 271 and the B-phase switch module 272 are electrically connected in parallel between the third P bus bar 133 and the second N bus bar 142.

In addition, in FIG. 1, connection parts of various bus bars with electric elements are shown by white circles. These connection parts are electrically connected, for example, by bolts or welding.

Filter capacitor 250 has a capacitor element 280, a first electrode terminal 281, and a second electrode terminal 282. Capacitor element 280 includes a dielectric and two electrodes sandwiching the dielectric. The first electrode terminal 281 is connected to one of these two electrodes. A second electrode terminal 282 is connected to the other of these two electrodes.

As shown in FIG. 1, one end of the first P bus bar 131 is electrically connected to the positive electrode of the battery 10. One end of the first N bus bar 141 is electrically connected to the negative electrode of the battery 10. A first electrode terminal 281 of a filter capacitor 250 is connected to this first P bus bar 131 . A second electrode terminal 282 is connected to the first N bus bar 141 . Thereby, filter capacitor 250 is electrically connected to battery 10.

One end of the second P bus bar 132 is connected to the other end of the reactor 260. The other end side of the second P bus bar 132 is branched into two. One of these two branched ends is connected to the A-phase switch module 271, and the remaining end is connected to the B-phase switch module 272.

The A-phase switch module 271 and the B-phase switch module 272 have equivalent components. Therefore, in the following, the A-phase switch module 271 will be explained in detail, and the explanation of the B-phase switch module 272 will be omitted. Also in the drawings, the B-phase switch module 272 is shown in a simplified manner.

The A-phase switch module 271 has a high-side switch 291 and a low-side switch 292. Further, the A-phase switch module 271 has a high-side diode 293 and a low-side diode 294.

In this embodiment, n-channel IGBTs are used as the high-side switch 291 and the low-side switch 292. IGBT is an abbreviation for Insulated Gate Bipolar Transistor.

As shown in FIG. 1, the emitter electrode of the high-side switch 291 and the collector electrode of the low-side switch 292 are connected. Thereby, the high side switch 291 and the low side switch 292 are electrically connected in series.

Furthermore, a cathode electrode of a high-side diode 293 is connected to a collector electrode of the high-side switch 291 . An anode electrode of a high side diode 293 is connected to an emitter electrode of the high side switch 291. As a result, the high-side diode 293 is connected in antiparallel to the high-side switch 291.

Similarly, the cathode electrode of a low-side diode 294 is connected to the collector electrode of the low-side switch 292. An anode electrode of a low-side diode 294 is connected to an emitter electrode of the low-side switch 292 . As a result, a low-side diode 294 is connected in antiparallel to the low-side switch 292 .

The A-phase switch module 271 has a collector terminal 295, an emitter terminal 296, an output terminal 297, and a gate terminal 298 in addition to the semiconductor element described above.

One end of the collector terminal 295 is connected to the collector electrode of the high side switch 291. The other end of the collector terminal 295 is connected to the third P bus bar 133.

One end of emitter terminal 296 is connected to the emitter electrode of low side switch 292. The other end of the emitter terminal 296 is connected to the second N bus bar 142.

Due to such electrical connection, the high side switch 291 and the low side switch 292 are connected in series in order from the third P bus bar 133 to the second N bus bar 142. Collector terminal 295 and emitter terminal 296 correspond to connection terminals.

One end of the output terminal 297 is commonly connected to the emitter electrode of the high-side switch 291 and the collector electrode of the low-side switch 292. The other end of the output terminal 297 is connected to the second P bus bar 132.

Through such electrical connection, the reactor 260 is connected to the midpoint between the high side switch 291 and the low side switch 292.

One end of the gate terminal 298 is individually connected to the gate electrodes of the high-side switch 291 and the low-side switch 292. The other end of gate terminal 298 is connected to control board 240.

This electrical connection allows a control signal from the control board 240 to be input to the gate electrodes of the high-side switch 291 and the low-side switch 292, respectively. This control signal controls the energization state and cutoff state of the high-side switch 291 and the low-side switch 292, respectively.

Note that as the constituent material of the semiconductor element included in the converter 210, a semiconductor such as Si and a wide gap semiconductor such as SiC can be used. The constituent material of the semiconductor element is not particularly limited.

<Inverter>
Inverter 220 has a smoothing capacitor 310 and a discharge resistor 320. Further, the inverter 220 includes a U1 phase switch module 273 to a W2 phase switch module 278 of the switch module 270. These various components are electrically connected in parallel between the third P bus bar 133 and the second N bus bar 142.

Smoothing capacitor 310 includes the same components as filter capacitor 250. That is, the smoothing capacitor 310 has a capacitor element 280, a first electrode terminal 281, and a second electrode terminal 282. In FIG. 1, the symbols of the capacitor element 280, the first electrode terminal 281, and the second electrode terminal 282 included in the smoothing capacitor 310 are omitted to avoid complication of notation.

Smoothing capacitor 310 includes more capacitor elements 280 than filter capacitor 250 . Therefore, the smoothing capacitor 310 has a larger storage capacity than the filter capacitor 250.

The first electrode terminal 281 of the smoothing capacitor 310 is connected to the third P bus bar 133. The second electrode terminal 282 is connected to the second N bus bar 142. Smoothing capacitor 310 is brought into a fully charged state when power conversion circuit 200 is used. At this time, smoothing capacitor 310 smoothes the current flowing between converter 210 and inverter 220. Smoothing capacitor 310 is placed in a discharged state when power conversion circuit 200 is not in use.

The discharge resistor 320 functions to convert the charge stored in the smoothing capacitor 310 into thermal energy when the power conversion circuit 200 is not in use. One end of the discharge resistor 320 is connected to the third P bus bar 133. The other end of the discharge resistor 320 is connected to the second N bus bar 142.

Smoothing capacitor 310 and discharge resistor 320 are connected via third P bus bar 133 and second N bus bar 142. A closed loop including a smoothing capacitor 310 and a discharge resistor 320 is configured. When the power conversion circuit 200 is not in use, the charge stored in the smoothing capacitor 310 flows through the above-described closed loop. Thereby, the charge (electrical energy) stored in the smoothing capacitor 310 is converted into thermal energy by the discharge resistor 320.

Each of the U1 phase switch module 273 to W2 phase switch module 278 has the same components as the A phase switch module 271. Therefore, in FIG. 1, each of the U1 phase switch module 273 to W2 phase switch module 278 is shown in a simplified manner.

Collector terminals 295 of each of the U1 phase switch module 273 to W2 phase switch module 278 are connected to the third P bus bar 133. Emitter terminal 296 is connected to second N bus bar 142 . Thereby, the high side switch 291 and the low side switch 292 are connected in series in order from the third P bus bar 133 to the second N bus bar 142.

The output terminal 297 of the U1 phase switch module 273 is connected to the U1 phase stator coil via the U1 phase bus bar 151. An output terminal 297 of the V1 phase switch module 274 is connected to the V1 phase stator coil via the V1 phase bus bar 152. An output terminal 297 of the W1 phase switch module 275 is connected to the W1 phase stator coil via the W1 phase bus bar 153. As a result, the U1 phase switch module 273 to W1 phase switch module 275 are individually connected to the U1 phase stator coil to W1 phase stator coil of the first MG 41.

Similarly, the output terminal 297 of the U2 phase switch module 276 is connected to the U2 phase stator coil via the U2 phase bus bar 154. An output terminal 297 of the V2 phase switch module 277 is connected to the V2 phase stator coil via the V2 phase bus bar 155. An output terminal 297 of the W2 phase switch module 278 is connected to the W2 phase stator coil via the W2 phase bus bar 156. As a result, the U2-phase switch module 275 to W2-phase switch module 278 are individually connected to the U2-phase stator coil to W2-phase stator coil of the second MG 42.

Gate terminals 298 of each of the U1 phase switch module 274 to W2 phase switch module 278 are connected to the control board 240. A high-side switch 291 and a low-side switch 292 included in these six switch modules are controlled by the control board 240 to be in an energized state and an energized state.

Note that as the constituent material of the semiconductor element included in the inverter 220, a semiconductor such as Si and a wide gap semiconductor such as SiC can be used. The constituent materials of the semiconductor elements included in inverter 220 and the constituent materials of the semiconductor elements included in converter 210 may be the same or different.

<Control board>
As described above, the control board 240 includes the gate driver 241 and the EVECU 242. The EVECU 242 has a storage section 243 and a calculation section 244 shown in FIG.

The storage unit 243 is a non-transitional physical storage medium that non-temporarily stores data and programs readable by a computer or processor. The storage unit 243 includes volatile memory and nonvolatile memory. The storage unit 243 stores various information input to the control board 240 and processing results of the calculation unit 244. The storage unit 243 stores various programs and various reference values for the calculation process by the calculation unit 244.

The calculation unit 244 includes a processor. The calculation unit 244 stores various information input to the control board 240 in the storage unit 243. The calculation unit 244 executes various calculation processes based on the information stored in the storage unit 243.

Arithmetic unit 244 generates a control signal. This control signal is amplified by the gate driver 241. By this amplified control signal, switches included in each of system switch 20, converter 210, and inverter 220 are controlled to be in the energized state and in the energized state.

<Switch control>
When driving the motor 40, the EVECU 242 controls various switches included in the converter 210 and the inverter 220 to turn on and off.

EVECU 242 generates pulse signals as control signals for switches included in converter 210 and inverter 220. The EVECU 242 adjusts the on-duty ratio and frequency of this pulse signal. The on-duty ratio and frequency are determined based on the physical quantity detected by the physical quantity sensor 230 and vehicle information input from other ECUs. This vehicle information includes the rotation angles of the first MG 41 and the second MG 42, the target torques of the first MG 41 and the second MG 42, the SOC of the battery 10, and the like.

When boosting or lowering the DC power, EVECU 242 selects at least one of A-phase switch module 271 and B-phase switch module 272 included in converter 210.

Which of the A-phase switch module 271 and the B-phase switch module 272 to select can be determined based on, for example, the state of these two switch modules, the difference in performance, and the vehicle state. For example, if one of the two switch modules is hotter than the other, it is determined that the other switch module is selected.

When boosting the DC power supplied from the battery 10, the EVECU 242 fixes the high side switch 291 included in the selected switch module in a cut-off state. At the same time, the EVECU 242 sequentially switches the low-side switch 292 between an energized state and an energized state.

When stepping down the DC power supplied from the inverter 220, the EVECU 242 fixes the low-side switch 292 included in the selected switch module in a cut-off state. At the same time, the EVECU 242 sequentially switches the high-side switch 291 between an energized state and an energized state.

When powering each of the first MG 41 and the second MG 42, the EVECU 242 performs PWM control on the high side switch 291 and the low side switch 292 included in the U1 phase switch module 273 to W2 phase switch module 278. As a result, the inverter 220 generates three-phase alternating current.

When the first MG 41 and the second MG 42 generate power (regenerate), the EVECU 242 stops outputting control signals to the high-side switch 291 and the low-side switch 292 included in the U1-phase switch module 273 to W2-phase switch module 278, for example. As a result, the AC power generated by the first MG 41 and the second MG 42 passes through the diodes included in the U1 phase switch module 273 to W2 phase switch module 278. As a result, AC power is converted to DC power.

<Switch>
As described above, the high-side switch 291 and the low-side switch 292 included in each of the A-phase switch module 271 to the W2-phase switch module 278 are used for power conversion. For this reason, these switches are also called power semiconductor elements.

The types of switches employed as the high-side switch 291 and the low-side switch 292 are not limited to IGBTs. For example, MOSFETs can be used as the high-side switch 291 and the low-side switch 292. MOSFET is an abbreviation for Metal Oxide Semiconductor Field Effect Transistor.

The types of switches included in each of the A-phase switch module 271 to W2-phase switch module 278 may be different. For example, when these eight switch modules in total are divided into two sets, the type of switch included in one of the two sets may be IGBT, and the type of switch included in the remaining one may be MOSFET.

For example, the types of switches included in the A-phase switch module 271 and the switches included in the B-phase switch module 272 may be different. The types of switches included in the U1 phase switch module 273 to W1 phase switch module 275 and the switches included in the U2 phase switch module 276 to W2 phase switch module 278 may be different.

Furthermore, the constituent materials of the switches included in each of the A-phase switch module 271 to W2-phase switch module 278 may be different. For example, when these eight switch modules in total are divided into two sets, the constituent material of the switch included in one of the two sets may be Si, and the constituent material of the switch included in the remaining one set may be SiC.

For example, the constituent materials of the switches included in the A-phase switch module 271 and the switches included in the B-phase switch module 272 may be different. The constituent materials of the switches included in the U1 phase switch module 273 to W1 phase switch module 275 and the switches included in the U2 phase switch module 276 to W2 phase switch module 278 may be different.

<DCDC converter>
The power conversion circuit 200 includes a DC/DC converter 330 in addition to the converter 210 and the inverter 220 as circuit elements that perform power conversion. In-vehicle system 100 includes a branch bus bar 160 in addition to the bus bars described above. The branch bus bar 160 includes a first branch bus bar 161 and a second branch bus bar 162. In the drawings, the DCDC converter 330 is expressed as DCDC.

As shown in FIG. 1, the DCDC converter 330 is connected to the first P bus bar 131 via the first branch bus bar 161. The DCDC converter 330 is connected to the first N bus bar 141 via the second branch bus bar 162.

The first branch bus bar 161 is connected to the first P bus bar 131. The second branch bus bar 162 is connected to the first N bus bar 141 . Due to this electrical connection configuration, DCDC converter 330 and converter 210 are electrically connected in parallel to battery 10 .

When the first SMR 21 and the second SMR 22 are energized, the DCDC converter 330 and the battery 10 are electrically connected. DCDC converter 330 steps down the DC power supplied from battery 10 . The DC/DC converter 330 then supplies this stepped-down DC power to the electric vehicle's low-voltage battery, speakers, air conditioner, power window, power steering device, and other in-vehicle electrical components.

<Assy>
As described above based on FIG. 1, the power conversion device 30 has the power conversion circuit 200 as a circuit component. In addition, the power converter 30 includes an assembly 400 as a mechanical component.

Hereinafter, in describing the assembly 400, three directions that are orthogonal to each other will be referred to as an x direction, a y direction, and a z direction. In the drawings, "directions" are omitted and are simply expressed as x, y, and z.

The assembly 400 accommodates and supports various components of the power conversion circuit 200, and also cools them. Assembly 400 includes a housing 410, an electrical connector 420, a cooler 430, a capacitor case 440, and a busbar case 450.

Housing 410 accommodates P bus bar 130 to branch bus bar 160, components of power conversion circuit 200, electrical connector 420, cooler 430, capacitor case 440, and bus bar case 450, respectively. Further, the housing 410 cools the contents stored in the housing 410 together with the cooler 430.

A wire harness electrically connected to an on-vehicle electrical component is connected to the electrical connector 420. Electrical connector 420 includes a shunt busbar 160. Electrical connector 420 also includes an output connector. Electrical connector 420 is bolted to capacitor case 440 and housing 410.

The cooler 430 accommodates each of the A-phase switch module 271 to the W2-phase switch module 278. The cooler 430 determines the positions of these eight A-phase switch modules 271 to W2-phase switch modules 278. At the same time, the cooler 430 cools these eight A-phase switch modules 271 to W2-phase switch modules 278. Cooler 430 is fixed to housing 410 by elastic force generated by a spring body.

Capacitor case 440 houses filter capacitor 250 and smoothing capacitor 310. At the same time, the capacitor case 440 supports the first P bus bar 131, the third P bus bar 133, the first N bus bar 141, and the second N bus bar 142 that are connected to these capacitors. Capacitor case 440 is bolted to housing 410.

The bus bar case 450 supports the second P bus bar 132 and the phase bus bar 150. Busbar case 450 is bolted to housing 410.

<Housing>
As shown in FIGS. 2 to 7, the housing 410 includes a lower housing 510, an upper housing 520, and a cover 530. The lower housing 510 and the upper housing 520 are manufactured from metal materials such as aluminum and iron. The cover 530 is made of resin material or metal material.

The lower housing 510 has a box shape with a bottom. Upper housing 520 is annular. The cover 530 has a box shape with a bottom. In the z direction, the lower housing 510 and the cover 530 are lined up with the upper housing 520 in between.

As shown in FIGS. 8 to 11, the opening of the lower housing 510 and one of the two openings of the upper housing 520 are arranged side by side in the z direction. In this arrangement, the upper housing 520 is connected to the lower housing 510 by bolts or the like.

Through such a connection, the hollow spaces of the lower housing 510 and the upper housing 520 are communicated with each other. Further, as shown in FIG. 10, for example, some of the items stored in the upper housing 520 protrude outside the upper housing 520. A part of the stored items that have protruded out of the upper housing 520 are stored in the lower housing 510.

The other side of the two openings of the upper housing 520 and the opening of the cover 530 are arranged side by side in the z direction. In this arrangement, the cover 530 is connected to the upper housing 520 with bolts or the like.

Due to this connection, the space defined (divided) by the lower housing 510 and the upper housing 520 is closed by the cover 530. A storage space of the housing 410 is defined by the lower housing 510, the upper housing 520, and the cover 530, respectively.

Note that, as shown in FIGS. 2 to 11, the assembly 400 has many holes. 2 to 7 illustrate a closing member that closes some of these many holes. In FIGS. 8 to 11, illustration of this closing member is omitted.

<Lower housing>
Lower housing 510 has a bottom wall 511 and a lower wall 512. A lower wall 512 stands up from the bottom wall 511 in the z direction.

As shown in FIG. 12, the bottom wall 511 has an inner bottom wall 517 and an outer bottom wall 518. The inner bottom wall 517 has an inner bottom surface that partitions a part of the storage space, and an outer bottom surface 517b on the back side thereof. An outer bottom wall 518 is connected to the inner bottom wall 517 in a manner that covers a part of this outer bottom surface 517b. This connection forms a gap (flow path) between the inner bottom wall 517 and the outer bottom wall 518 for flowing the refrigerant. The flow path will be described later.

<Bottom hole>
A bottom hole 517c that opens to the inner bottom surface and the outer bottom surface 517b is formed in a region of the inner bottom wall 517 that does not face the outer bottom wall 518 in the z direction. A positive electrode terminal 110a and a negative electrode terminal 110b are provided on the inner bottom side of this bottom hole 517c.

A first P bus bar 131 is electrically connected to the positive terminal 110a. A first N bus bar 141 is electrically connected to the negative terminal 110b. A power wire harness 110 is connected to the positive terminal 110a and the negative terminal 110b.

<Lower wall>
As shown in FIGS. 8 to 11, the lower wall 512 stands up in the z direction from the inner bottom surface. The lower wall 512 extends annularly in the circumferential direction around the z direction. As shown in FIGS. 8 to 11, the lower wall 512 has an inner surface that partitions a portion of the storage space, and an outer surface on the back side thereof. An opening of the lower housing 510 is defined by a distal end side of the lower wall 512 that is spaced apart from the bottom wall 511 .

To explain in detail, the lower wall 512 has a front lower wall 513 and a rear lower wall 514 that are lined up in the x direction, and a left lower wall 515 and a right lower wall 516 that are lined up in the y direction. A lower front wall 513, a lower right wall 516, a lower rear wall 514, and a lower left wall 515 are connected in order in the circumferential direction around the z direction. Thereby, the lower wall 512 extends annularly in the circumferential direction.

<Flow path>
As described above, a flow path is formed between the inner bottom wall 517 and the outer bottom wall 518. As shown in FIG. 11, an inflow hole 511a and a discharge hole 511b are formed on the bottom wall 511 side of the lower left wall 515. The inflow hole 511a and the discharge hole 511b are lined up in the x direction. The inflow hole 511a is located on the front lower wall 513 side. The discharge hole 511b is located on the rear lower wall 514 side.

The flow path extends from the inflow hole 511a to the lower right wall 516 side. After this, the flow path extends from the front lower wall 513 side to the rear lower wall 514 side. The flow path extends toward the discharge hole 511b.

In this way, the upstream region of the flow path extending from the inflow hole 511a and the downstream region of the flow path extending toward the discharge hole 511b each extend in the y direction. The middle region of the channel extends in the x direction. The upstream and downstream areas of the flow path are spaced apart from each other in the x direction.

A refrigerant that has passed through the cooler 430 is supplied to this flow path. The bottom wall 511 side of the housing 410 is cooled by this coolant. The refrigerant of this embodiment is an antifreeze liquid such as LLC, which has a larger heat capacity than water. A gas such as air can also be used as the refrigerant.

Note that a connecting pipe 519 that extends in the x direction so as to be spaced apart from the lower housing 510 is integrally connected to the bottom wall 511 side of the lower left wall 515. The hollow of the connecting pipe 519 and the discharge hole 511b communicate with each other.

The refrigerant that flows into the channel from the inflow hole 511a and flows through the channel reaches the connecting pipe 519. The refrigerant that has reached the connecting pipe 519 is supplied to a heat exchanger (not shown). This heat exchanger lowers the temperature of the refrigerant. This refrigerant whose temperature has decreased is returned to the cooler 430. The heat exchanger is, for example, a radiator.

<Motor connection hole>
As shown in FIG. 8, the lower front wall 513 is formed with a motor connection hole 513c that opens on the inner and outer surfaces. The motor connection hole 513c is located closer to the left lower wall 515 than the right lower wall 516 in the y direction. When the upper housing 520 is connected to the lower housing 510, as shown in FIG. 3, a bus bar case 450 is provided on the inner side of the motor connection hole 513c.

The bus bar case 450 is provided with U1 phase bus bars 151 to W2 phase bus bars 156. The ends of these six bus bars are aligned with the motor connection hole 513c in the x direction. The ends of the six bus bars are located in the projection area of the motor connection hole 513c in the x direction. A power wire harness 120 is connected to these six bus bars. The bus bar and the power wire harness 120 are electrically connected by a bolt inserted into the storage space through the motor connection hole 513c.

The second P bus bar 132 is provided in the bus bar case 450. The end of the second P bus bar 132 is located in the projection area of the motor connection hole 513c in the x direction. An end of this second P bus bar 132 is electrically connected to a second relay bus bar 262 of the reactor 260. The second P bus bar 132 and the second relay bus bar 262 are electrically connected by a bolt inserted into the storage space through the motor connection hole 513c.

<Lower module>
A reactor 260 and a DCDC converter 330 are provided in the lower housing 510. This constitutes the lower module.

Reactor 260 and DCDC converter 330 are connected to lower housing 510 by bolts. The reactor 260 and the DCDC converter 330 are lined up in the y direction.

<Reactor>
An inner bottom wall 517 of the bottom wall 511 is formed with a recess for installing the reactor 260 therein. This depression is recessed from the inner bottom surface toward the outer bottom surface 517b. In other words, a part of the inner bottom wall 517 stands up in a direction from the outer bottom surface 517b toward the inner bottom surface so as to form an annular shape in the circumferential direction around the z direction.

The depression opens into a space surrounded by a lower wall 512. The concave portion of the inner bottom wall 517 defines a part of the flow path. Note that the constituting portion of the depression does not need to partition a part of the flow path.

The depression is located on the lower left wall 515 side in the y direction. The recess is located at the center of the lower housing 510 in the x direction. On the other hand, the bottom hole 517c described above is located on the lower right wall 516 side in the y direction. Therefore, the reactor 260 provided in the depression and the positive electrode terminal 110a provided in the bottom hole 517c are separated in the y direction.

The reactor 260 includes a winding core, an insulated wire wound around the winding core, two terminals connected to the ends of the insulated wire, and a resin that integrally connects these. A winding core around which an insulated wire is wound is provided in the recess. Molten resin is poured into this depression. This resin is then solidified. Thereby, the reactor 260 is provided in the recess of the bottom wall 511.

The two terminals mentioned above are exposed outside the resin. The reactor 260 has a first relay bus bar and a second relay bus bar 262 connected to these two terminals. A first relay bus bar is connected to one of the two terminals. A second relay bus bar 262 is connected to the other of the two terminals.

The first relay bus bar extends from the depression toward the bottom hole 517c in the y direction. The number of the first relay bus bars may be one or more. A positive terminal 110a is connected to this first relay bus bar.

The second relay bus bar 262 extends from the depression toward the motor connection hole 513c side of the front lower wall 513 in the x direction. That is, the second relay bus bar 262 extends toward the bus bar case 450. The second P bus bar 132 is connected to this second relay bus bar 262 .

<DCDC converter>
DCDC converter 330 includes a lower wiring board and an electronic element provided on this lower wiring board. The lower wiring board has a flat plate shape with a thin thickness in the z direction.

The lower wiring board is located closer to the lower right wall 516 than the lower left wall 515 in the y direction. The lower wiring board is aligned with the middle region side of the flow path described above in the z direction. DCDC converter 330 is electrically connected to electrical connector 420.

<Upper housing>
As shown in FIG. 13, the upper housing 520 has an annular wall 521 and an inner wall 522. The annular wall 521 extends annularly in the circumferential direction around the z direction. The annular wall 521 has an inner annular surface 521a that partitions a part of the storage space, and an outer annular surface 521b that is exposed to the external space. Inner wall 522 is connected to inner annular surface 521a.

As shown in FIG. 13 and the like, to explain in detail, the annular wall 521 has a front upper wall 523 and a rear upper wall 524 arranged in the x direction, and an upper left wall 525 and an upper right wall 526 arranged in the y direction. The front upper wall 523, the right upper wall 526, the rear upper wall 524, and the left upper wall 525 are connected in order in the circumferential direction around the z direction. Thereby, the annular wall 521 extends annularly in the circumferential direction.

<Connector hole>
As shown in FIGS. 4 and 9, a connector hole 521c is formed on the rear upper wall 524 side of the upper right wall 526 and opens to the inner annular surface 521a and the outer annular surface 521b. An electrical connector 420 is provided on the inner annular surface 521a side of this connector hole 521c. A connector of a wire harness electrically connected to an in-vehicle electrical component is inserted into the connector hole 521c through an opening on the outer annular surface 521b side. This connector is connected to electrical connector 420.

<Pipe hole>
As shown in FIG. 11, the upper left wall 525 is formed with a first tube hole 521d and a second tube hole 521e that open to the inner annular surface 521a and the outer annular surface 521b. The first tube hole 521d and the second tube hole 521e are lined up in the x direction. The first tube hole 521d is located on the rear upper wall 524 side. The second tube hole 521e is located on the front upper wall 523 side.

The supply pipe 610 of the cooler 430 is passed from the inner annular surface 521a side of this first pipe hole 521d to the outer annular surface 521b side. The discharge pipe 620 of the cooler 430 is passed from the inner annular surface 521a side of the second pipe hole 521e to the outer annular surface 521b side.

For example, as shown in FIGS. 3, 5, and 6, the discharge pipe 620 and the inflow hole 511a are communicated via a relay pipe 521f. As a result, the refrigerant flowing through the cooler 430 and discharged into the relay pipe 521f is supplied to the flow path of the lower housing 510.

<Inner wall>
The inner wall 522 divides the space defined by the annular wall 521 into a lower space on the lower housing 510 side and an upper space on the cover 530 side in the z direction. A plurality of holes are formed in the inner wall 522 and open in the z direction. The lower space and the upper space communicate with each other through the plurality of holes.

<Upper module>
As shown in FIGS. 8-11, 13, etc., the upper housing 520 is provided with an electrical connector 420, a cooler 430, a capacitor case 440, and a busbar case 450. Further, as shown in FIG. 16, the upper housing 520 is provided with a control board. This constitutes an upper module.

Electrical connector 420, cooler 430, capacitor case 440, and busbar case 450 are each provided in the lower space. Electrical connector 420, capacitor case 440, and busbar case 450 are each bolted to upper housing 520. The cooler 430 is fixed to the upper housing 520 by the elastic force of the spring body described above. This spring body is provided between the cooler 430 and the extension portion of the inner wall 522 in the z direction.

At least some of the bolt-fastening locations of capacitor case 440 and bus bar case 450 to upper housing 520 are located outside upper housing 520. This bolted portion is housed in the lower housing 510 when the upper housing 520 is connected to the lower housing 510.

The switch module 270 is housed in the cooler 430 . A temperature sensor 232 is provided in the switch module 270. A voltage sensor 231 is provided in the capacitor case 440. A current sensor 233 is provided in the busbar case 450.

Voltage sensor 231 has voltage detection terminal 234 . The temperature sensor 232 has a temperature detection terminal 235. Current sensor 233 has a current detection terminal 236.

A gate terminal 298 and a temperature detection terminal 235 extend from the switch module 270 in the z direction. A voltage detection terminal 234 extends from the capacitor case 440 in the z direction. A current detection terminal 236 extends from the busbar case 450 in the z direction.

Each of the gate terminal 298, temperature detection terminal 235, voltage detection terminal 234, and current detection terminal 236 extends from the lower space toward the upper space through a plurality of holes formed in the inner wall 522.

As shown in FIG. 16, a control board 240 is provided in the upper space. The control board 240 includes an upper wiring board 245 shown in FIG. 14, and electronic elements that constitute the gate driver 241 and the EVECU 242. In the drawings, illustration of this electronic element is omitted.

A through hole 246 penetrating in the z direction is formed in the upper wiring board 245. A gate terminal 298, a temperature detection terminal 235, a voltage detection terminal 234, and a current detection terminal 236 are inserted into this through hole 246, respectively. These terminals are connected to the upper wiring board 245 via solder.

Although not shown, the upper wiring board 245 is provided with a guide portion for guiding insertion of the terminal into the through hole 246. A guide hole penetrating in the z direction is formed in this guide portion. This guide hole and the through hole 246 communicate in the z direction. The various terminals described above are passed through this guide hole.

Further, the upper wiring board 245 is provided with a fixing part for increasing the connection strength between the terminal inserted into the through hole 246 and the upper wiring board 245. A fixing hole penetrating in the z direction is formed in this fixing part. Various terminals passed through this fixing hole are connected to the fixing part by solder.

A signal connector 247 shown in FIG. 15 is connected to the upper wiring board 245. A wire harness connector electrically connected to another ECU is connected to this signal connector 247.

As shown in FIG. 13, the electrical connector 420 and the cooler 430 are lined up in the y direction. Electrical connector 420 is located on the upper right wall 526 side. The cooler 430 is located on the left upper wall 525 side.

When the upper housing 520 is connected to the lower housing 510, the electrical connector 420 is arranged to face the DCDC converter 330 in the z direction. The cooler 430 is arranged to face the reactor 260 in the z direction.

As shown in FIG. 13, the capacitor case 440 and the bus bar case 450 are lined up in the x direction with the cooler 430 interposed therebetween. The capacitor case 440 is located on the rear upper wall 524 side. Cooler 430 is located at the center of capacitor case 440 in the x direction. The busbar case 450 is located on the front upper wall 523 side.

Although not shown, portions of each of the capacitor case 440 and the bus bar case 450 protrude outside the upper housing 520. The portions of the capacitor case 440 and the busbar case 450 protruding from the upper housing 520 are housed in the lower housing 510 when the upper housing 520 is connected to the lower housing 510. Capacitor case 440 is provided within lower housing 510 between rear lower wall 514 and a recess in which reactor 260 is provided. The busbar case 450 is provided within the lower housing 510 between the recess and the front lower wall 513.

<Cover>
As shown in FIGS. 10, 11, etc., the cover 530 has a top wall 531 and an edge wall 532. An edge wall 532 stands up from the ceiling wall 531 in the z direction.

The ceiling wall 531 has a flat shape with a small thickness in the z direction. The top wall 531 has an inner top surface that partitions a part of the storage space and an outer top surface 531b on the back side thereof. As shown in FIG. 2, a ceiling hole 531c is formed in the ceiling wall 531 and opens to an inner ceiling surface and an outer ceiling surface 531b. A signal connector 247 is provided in this ceiling hole 531c. As shown in FIGS. 3 to 6, the signal connector 247 projects from the storage space to the external space via the ceiling hole 531c.

The edge wall 532 stands up in the z direction from the inner top surface. The edge wall 532 extends annularly in the circumferential direction around the z direction. To explain in detail, the edge wall 532 has a front edge wall 533 and a rear edge wall 534 that are lined up in the x direction, and a left edge wall 535 and a right edge wall 536 that are lined up in the y direction. A leading edge wall 533, a right edge wall 536, a trailing edge wall 534, and a left edge wall 535 are connected in order in the circumferential direction around the z direction. As a result, the edge wall 532 extends annularly in the circumferential direction.

The opening of the cover 530 is defined by the end side of the edge wall 532 that is spaced apart from the top wall 531. An edge portion 537 is integrally connected to the tip side of this edge wall 532.

The edge 537 has a flat plate shape with a thin thickness in the z direction. The edge portion 537 extends from the distal end side of the edge wall 532 along a plane orthogonal to the z direction in a manner that is spaced apart from the hollow of the cover 530. A plurality of holes are formed in this edge 537 for bolting the cover 530 to the upper housing 520.

As described above, the ceiling wall 531 has a ceiling hole 531c formed therein. This ceiling hole 531c is located closer to the right edge wall 536 than the left edge wall 535 in the y direction. Therefore, the spatial distance and creepage distance between the ceiling hole 531c and the right edge wall 536 are shorter than the spatial distance and creepage distance between the ceiling hole 531c and the left edge wall 535.

That is, the spatial distance and creepage distance between the ceiling hole 531c and a portion of the edge 537 that extends from the right edge wall 536 in the y direction are the same as that of the ceiling hole 531c and the portion of the edge 537 that extends from the left edge wall 535 in the y direction. It is shorter than the spatial distance and creepage distance between the parts. The spatial distance and creepage distance between the ceiling hole 531c and the bolt located on the right edge wall 536 side in the y direction are the same as the spatial distance and creepage distance between the ceiling hole 531c and the bolt located on the left edge wall 535 side in the y direction. It is shorter than the creepage distance.

Due to this configuration, electromagnetic noise generated around the top hole 531c of the cover 530 easily flows to the upper housing 520 via the bolt located on the right edge wall 536 side in the y direction.

<Switch module>
As described above, each of the A-phase switch module 271 to the W2-phase switch module 278 includes the same components. These eight switch modules have a coating resin 600 shown in FIGS. 17 to 22.

The coating resin 600 covers the high side switch 291, the low side switch 292, the high side diode 293, the low side diode 294, and the temperature sensor 232. Further, the coating resin 600 covers one end side of each of the collector terminal 295, the emitter terminal 296, the output terminal 297, the gate terminal 298, and the temperature detection terminal 235. The other end sides of these terminals are exposed from the coating resin 600.

As shown in FIGS. 19 and 21, the coating resin 600 has a flat shape with a thin thickness in the y direction. The coating resin 600 has a rectangular parallelepiped shape. The coating resin 600 has a first main surface 600a and a second main surface 600b spaced apart in the y direction, a first side surface 600c and a second side surface 600d spaced apart in the x direction, and a first surface 600c and a second side surface 600d spaced apart in the z direction. It has a first end surface 600e and a second end surface 600f.

As shown in FIGS. 17 and 18, the other end sides of the gate terminal 298 and the temperature detection terminal 235 each protrude from the first end surface 600e. As shown in FIGS. 18 and 22, the other ends of the collector terminal 295, emitter terminal 296, and output terminal 297 protrude from the second end surface 600f. A collector terminal 295, an emitter terminal 296, and an output terminal 297 are arranged in this order from the first side surface 600c toward the second side surface 600d.

As shown in FIGS. 18 and 20, a heat sink 501 is embedded in the coating resin 600. One surface 501a of the heat sink 501 is exposed from each of the first main surface 600a and the second main surface 600b. This one surface 501a is flush with the above-mentioned main surface. Alternatively, one surface 501a slightly protrudes from the main surface in the y direction.

<Cooler>
The cooler 430 mainly functions to cool the A-phase switch module 271 to the W2-phase switch module 278. The main constituent material of the cooler 430 is a metal material with high thermal conductivity. For example, aluminum can be used as this metal material.

As shown in FIGS. 23 to 26, the cooler 430 includes a supply pipe 610, a discharge pipe 620, and a plurality of cooling pipes 630. The supply pipe 610 and the discharge pipe 620 are connected via a plurality of cooling pipes 630. Refrigerant is supplied to the supply pipe 610. This refrigerant flows from the supply pipe 610 to the discharge pipe 620 via a plurality of cooling pipes 630.

As shown in FIGS. 23 and 24, the supply pipe 610 and the discharge pipe 620 each extend in the y direction. As shown in FIG. 26, the supply pipe 610 and the discharge pipe 620 are spaced apart in the x direction. As shown in FIGS. 23 and 24, each of the plurality of cooling pipes 630 has a flat shape with a thin thickness in the y direction. As shown in FIGS. 25 and 26, each of the plurality of cooling pipes 630 extends in the x direction from the supply pipe 610 toward the discharge pipe 620.

As shown in FIG. 26, a supply port 611 in the supply pipe 610 through which the refrigerant is supplied from the outside and a discharge port 621 in the discharge pipe 620 through which the refrigerant supplied from the cooling pipe 630 is discharged to the outside are separated in the x direction. They are lined up. As shown in FIG. 23, the positions of the supply port 611 and the discharge port 621 in the y direction are the same.

Due to the configuration described above, the refrigerant supplied into the supply pipe 610 from the supply port 611 flows in the y direction away from the supply port 611. This refrigerant then flows into the cooling pipe 630 and flows in the x direction from the supply pipe 610 toward the discharge pipe 620. The refrigerant flowing into the discharge pipe 620 flows in the y direction toward the discharge port 621 of the discharge pipe 620.

In this way, the flow path through which the refrigerant flows in the cooler 430 has a folded shape. The flow path of the cooler 430 has a U-shape in a plane perpendicular to the z direction. The length of the distribution path increases as the separation distance in the y direction from the supply port 611 of the cooling pipe 630 forming a part of the distribution path increases.

<Power module>
The plurality of cooling pipes 630 are spaced apart from each other in the y direction. A gap is formed between two adjacent cooling pipes 630. A total of eight voids are configured in the cooler 430. A-phase switch module 271 to B-phase switch module 272 and U1-phase switch module 273 to W2-phase switch module 278 are individually provided in each of these eight gaps. This constitutes a power module. The y direction corresponds to the arrangement direction.

The first main surfaces 600a of each of the A-phase switch modules 271 to W2-phase switch modules 278 are located in the supply port 611 (discharge port 621) side in the y direction while being provided in the gap of the cooler 430. The first side surface 600c is located on the supply pipe 610 side in the x direction. The second side surface 600d is located on the discharge pipe 620 side.

One surface 501a of the heat sink 501 of each of the A-phase switch module 271 to W2-phase switch module 278 is in contact with the cooling pipe 630. The contact area between the two is increased by the elastic force provided by the spring body. Thereby, the heat generated in each of these eight switch modules can be conducted to the coolant via the cooling pipe 630. Note that a heat transfer member such as grease may be provided between the switch module and the cooling pipe 630.

In this embodiment, the A-phase switch module 271 and the B-phase switch module 272 are lined up in order in the direction away from the supply port 611 in the extending direction of the supply pipe 610. Next, a U1 phase switch module 273, a V1 phase switch module 274, and a W1 phase switch module 275 are lined up in this order. Next, a U2 phase switch module 276, a V2 phase switch module 277, and a W2 phase switch module 278 are lined up in this order.

Because of this arrangement, the A-phase switch module 271 and the B-phase switch module 272 are located upstream of the refrigerant flowing through the supply pipe 610 than the U1-phase switch module 273 to W1-phase switch module 275. The U1 phase switch module 273 to W1 phase switch module 275 are located upstream of the refrigerant flowing through the supply pipe 610 than the U2 phase switch module 276 to W2 phase switch module 278.

Further, the A-phase switch module 271 and the W2-phase switch module 278 are located at the end of the eight A-phase switch modules 271 to W2-phase switch modules 278 lined up in the y direction. The remaining six B-phase switch modules 272 to V2-phase switch modules 277 are located inside the eight A-phase switch modules 271 to W2-phase switch modules 278 lined up in the y direction.

Note that, for example, the V1 phase switch module 274, the U1 phase switch module 273, and the W1 phase switch module 275 may be arranged in this order. The V2 phase switch module 277, the U2 phase switch module 276, and the W2 phase switch module 278 may be arranged in this order.

<Power module arrangement>
As described above, the upper left wall 525 of the upper housing 520 is formed with a first tube hole 521d and a second tube hole 521e that are lined up in the x direction. The supply pipe 610 is passed from the inner annular surface 521a side of this first tube hole 521d to the outer annular surface 521b side. The discharge pipe 620 is passed from the inner annular surface 521a side of the second pipe hole 521e to the outer annular surface 521b side.

With this arrangement, the A-phase switch modules 271 to W2-phase switch modules 278 are lined up in order from the upper left wall 525 to the upper right wall 526 in the storage space. The collector terminals 295, emitter terminals 296, and output terminals 297 of these eight A-phase switch modules 271 to W2-phase switch modules 278 are arranged in order from the rear upper wall 524 toward the front upper wall 523 in the x direction. .

Due to this arrangement, the collector terminal 295 and the emitter terminal 296 are each located closer to the rear upper wall 524 than the output terminal 297 in the x direction. The output terminal 297 is located closer to the front upper wall 523 in the x direction than the collector terminal 295 and the emitter terminal 296, respectively.

That is, the collector terminal 295 and the emitter terminal 296 are each located on the capacitor case 440 side. The output terminal 297 is located on the busbar case 450 side.

As described above, the capacitor case 440 is provided with the third P bus bar 133 and the second N bus bar 142. The second P bus bar 132 and the phase bus bar 150 are provided in the bus bar case 450.

Therefore, the collector terminal 295 and the emitter terminal 296 are located on the third P bus bar 133 and second N bus bar 142 side. The output terminal 297 is located on the side of the second P bus bar 132 and the phase bus bar 150.

Due to this arrangement, an increase in the distance between the collector terminal 295 and the third P bus bar 133 is suppressed. The distance between the emitter terminal 296 and the second N bus bar 142 is suppressed from increasing. Extension of the distance between the output terminal 297 and the second P bus bar 132 is suppressed. Extension of the distance between the output terminal 297 and the phase bus bar 150 is suppressed.

In addition, in the external space outside the storage space, the supply port 611 of the supply pipe 610 and the discharge port 621 of the discharge pipe 620 are lined up in the x direction. The discharge port 621 of the discharge pipe 620 and the inflow hole 511a of the lower housing 510 are communicated with each other via a relay pipe 521f shown in FIG. 6, for example.

<Relay pipe>
The relay pipe 521f is made of resin. The relay pipe 521f extends away from the upper left wall 525 in the y direction, then extends in the z direction toward the lower left wall 515, and then extends in the y direction toward the lower left wall 515. In this way, the relay pipe 521f extends in a U-shape. Note that the relay pipe 521f may be made of metal.

One end of the relay pipe 521f is connected to the upper left wall 525 in such a manner that the hollow of the relay pipe 521f and the discharge port 621 communicate with each other. The other end of the relay pipe 521f is connected to the lower left wall 515 in such a manner that the hollow of the relay pipe 521f communicates with the inflow hole 511a. The end of the relay pipe 521f may be connected to the wall by, for example, screwing or bolting.

Due to the connection described above, the refrigerant that has flowed through the circulation path of the cooler 430 flows from the upper housing 520 side to the lower housing 510 side in the z direction via the relay pipe 521f. This refrigerant flows into the flow path of the lower housing 510.

<Capacitor module>
Next, the capacitor case 440 will be explained based on FIGS. 27 and 28. Capacitor case 440 is made of an insulating resin material. A filter capacitor 250 and a smoothing capacitor 310 are housed in a capacitor case 440. Further, the capacitor case 440 is provided with a first P bus bar 131, a third P bus bar 133, a first N bus bar 141, a second N bus bar 142, and a voltage detection terminal 234. This constitutes a capacitor module.

<Capacitor case>
To explain in detail, the capacitor case 440 includes a main body portion 441, a rib 442, a terminal block 443, and an arrangement portion 444.

<Body part>
The main body portion 441 houses the filter capacitor 250, the smoothing capacitor 310, the first P bus bar 131, the third P bus bar 133, the first N bus bar 141, the second N bus bar 142, and the voltage detection terminal 234. As shown in FIGS. 27 and 28, the main body portion 441 has a shape in which the length in the y direction is longer than the length in each of the x and z directions. The main body portion 441 has a front surface 441a and a rear surface 441b that are spaced apart from each other in the x direction, a left surface 441c and a right surface 441d that are spaced apart from each other in the y direction, and an upper surface 441e and a bottom surface 441f that are spaced apart from each other in the z direction.

<Rib>
The rib 442 is integrally connected to the main body portion 441. As shown in FIG. 28, three ribs 442 are integrally connected to the left surface 441c, right surface 441d, and rear surface 441b of the main body portion 441 in this embodiment. The rib 442 connected to the rear surface 441b is located closer to the upper surface 441e in the z direction than the rib 442 connected to the left surface 441c and the right surface 441d.

As shown in FIG. 28, a collar 442a having higher rigidity than the main body portion 441 is embedded in the rib 442. The collar 442a has an annular shape opening in the z direction. The hollow portion of this collar 442a is exposed from the rib 442. A shaft portion of a bolt for fixing the capacitor case 440 to the upper housing 520 is passed through the hollow of the rib 442.

<Terminal block>
As shown in FIGS. 27 and 28, the terminal block 443 is integrally connected to the main body portion 441. In this embodiment, one terminal block 443 is integrally connected to the lower surface 441f of the main body portion 441.

As shown in FIG. 27, the terminal block 443 is provided with respective ends of the first P bus bar 131 and the first N bus bar 141. A bolt hole opening in the z direction is formed in the terminal block 443. A threaded groove is formed on the wall surface that partitions this bolt hole.

A hole that communicates with the bolt hole described above in the z direction is formed in a portion of the terminal block 443 of each of the first P bus bar 131 and the first N bus bar 141.

When the capacitor case 440 is installed in the lower housing 510, the holes of the first P bus bar 131 and the first N bus bar 141, the bolt holes of the terminal block 443, and the positive terminal 110a and the negative terminal 110b are arranged side by side in the z direction. A hole opening in the z direction is also formed in each of the positive electrode terminal 110a and the negative electrode terminal 110b. The hole of this terminal also communicates with the hole of the bus bar and the bolt hole of the terminal block 443 in the z direction.

The shaft portion of a bolt for connecting the power supply wire harness 110 is passed through these three holes. This bolt is then fastened into the bolt hole. As a result, the first P bus bar 131, the first N bus bar 141, the positive terminal 110a, and the negative terminal 110b are electrically connected to the power supply wire harness 110. A reactor 260 is electrically connected to the power supply wire harness 110.

<Arrangement section>
As shown in FIGS. 27 and 28, the arrangement section 444 is integrally connected to the main body section 441. In this embodiment, one arrangement section 444 is integrally connected to the upper surface 441e of the main body section 441.

A discharge resistor 320 is provided on the surface of the arrangement portion 444. The discharge resistor 320 is a wiring pattern formed on a wiring board. The discharge resistor 320 is electrically connected to the third P bus bar 133 and the second N bus bar 142 in the capacitor case 440.

A portion of the voltage detection terminal 234 is provided inside the arrangement section 444 . The tip of the voltage detection terminal 234 extends in the z direction so as to be spaced apart from the arrangement portion 444 .

<1st P bus bar and 1st N bus bar>
Each of the first P bus bar 131 and the first N bus bar 141 protrudes from the main body portion 441. The first P bus bar 131 and the first N bus bar 141 are each provided on the right side 441d of the front surface 441a. The ends of these bus bars extend along the surface of the main body 441 from the front surface 441a toward the upper surface 441e and the lower surface 441f, respectively, while being bent as necessary.

Note that a portion of the first N bus bar 141 that is lined up with the first P bus bar 131 in the x direction is buried in the main body portion 441 to avoid contact with the first P bus bar 131. The first N bus bar 141 is electrically connected to the second N bus bar 142 through the main body portion 441. Note that it is also possible to employ a configuration in which the first N bus bar 141 and the second N bus bar 142 are integrally connected.

Portions of the first P bus bar 131 and the first N bus bar 141 extending toward the lower surface 441f are provided in the terminal block 443. The portions of the first P bus bar 131 and the first N bus bar 141 that extend toward the upper surface 441e are bent and extend in the x direction in a manner that they are spaced apart from the front surface 441a.

A hole communicating in the z direction is formed in a portion of each of the first P bus bar 131 and the first N bus bar 141 that extends in the x direction and is spaced apart from the front surface 441a. The shaft of a bolt for connecting to the electrical connector 420 is passed through this hole. This bolt is then fastened to electrical connector 420. Thereby, the first P bus bar 131 and the first N bus bar 141 are electrically connected to the branch bus bar 160 of the electrical connector 420. The first P bus bar 131 and the first N bus bar 141 are electrically connected to the DCDC converter 330.

<Arrangement of capacitor element>
As described above, filter capacitor 250 and smoothing capacitor 310 each have a capacitor element. In this embodiment, filter capacitor 250 has one capacitor element. Smoothing capacitor 310 has two capacitor elements. In the drawing, these three capacitor elements are indicated by broken lines.

The three capacitor elements have a columnar shape with the x direction as the axial direction. These three capacitor elements are arranged in the y direction within the main body portion 441. The capacitor element of the filter capacitor 250 is located on the right side 441d of the main body 441 in the y direction. The capacitor element of the smoothing capacitor 310 is located on the left side 441c of the main body 441 in the y direction.

As shown in FIG. 28, a rib 442 connected to the rear surface 441b of the main body portion 441 is located between the capacitor element of the filter capacitor 250 and the capacitor element of the smoothing capacitor 310.

Thereby, the heat generated in the filter capacitor 250 and the smoothing capacitor 310 is transferred to the upper housing 520 via the bolt passed through the rib 442 connected to the rear surface 441b. Temperature increases in filter capacitor 250 and smoothing capacitor 310 are suppressed.

The distance in the y direction between the capacitor element of the filter capacitor 250 and the capacitor element of the smoothing capacitor 310 is approximately the length in the y direction of the rib 442 connected to the rear surface 441b. The distance between these two capacitor elements in the y direction is D1.

On the other hand, the distance in the y direction between the two capacitor elements of the filter capacitor 250 is D2. The distance D2 is shorter than the distance D1. In other words, the distance D1 is longer than the distance D2.

Due to this distance relationship, thermal interference between filter capacitor 250 and smoothing capacitor 310 is suppressed.

<Connection of capacitor element>
Each capacitor element has electrodes on two end faces spaced apart in the x direction. A first electrode terminal is connected to one of these two electrodes. A second electrode terminal is connected to the other of the two electrodes.

In this embodiment, the first electrode terminal is located on the rear surface 441b side. A second electrode terminal is located on the front surface 441a side. In the main body portion 441 , the first P bus bar 131 is connected to the first electrode terminal of the filter capacitor 250 . A third P bus bar 133 is connected to the first electrode terminal of the smoothing capacitor 310 . A second N bus bar 142 is connected to the second electrode terminal of each of the filter capacitor 250 and the smoothing capacitor 310.

Two capacitor elements included in the smoothing capacitor 310 are connected in parallel between the third P bus bar 133 and the second N bus bar 142. The total capacitance of these two capacitor elements is the capacitance of the smoothing capacitor 310.

<3rd P bus bar>
The third P bus bar 133 is manufactured by pressing a metal flat plate. The third P bus bar 133 has a first electrode portion.

As shown in FIG. 27, a portion of the third P bus bar 133 is exposed from the front surface 441a of the main body portion 441. The entire first electrode section is housed in the main body section 441.

The portion of the third P bus bar 133 exposed from the front surface 441a has a first upper surface and a first lower surface that are aligned in the z direction. Although not shown, a first through hole is formed in the exposed portion of the third P bus bar 133 and penetrates through the first upper surface and the first lower surface. In this embodiment, a total of eight first through holes are formed in the third P bus bar 133. These eight first through holes are spaced apart from each other in the y direction. Eight first through holes are arranged in one row and eight columns with the x and y directions as matrix directions.

Although not shown, the third P bus bar 133 is integrally connected with a first connecting portion that stands up in the z direction from the annular side surface that partitions the first through hole toward the bottom of the first lower surface. . In this embodiment, a total of eight first connection parts are spaced apart and lined up in the y direction.

Although not shown, the length of the first electrode portion in the y direction is longer than the portion exposed from the front surface 441a of the third P bus bar 133. The part of the first electrode part that extends in the y direction while including the part connected to the exposed part is the first connecting part, and the part of the first electrode part that extends in the y direction and includes the part unconnected to the exposed part is the first part. It is a non-connected part. One first connected portion and one first unconnected portion are connected side by side in the y direction. The creepage distance between the first connecting portion and the first connecting portion is shorter than the creeping distance between the first unconnected portion and the first connecting portion.

<Insulating board>
An insulating plate made of an insulating resin material is provided on the first lower surface of the exposed portion of the third P bus bar 133. The insulating plate has a flat plate shape with a thin thickness in the z direction.

A second through hole penetrating in the z direction is formed in the insulating plate. Further, the insulating plate is formed with an annular portion extending annularly downward along the z direction around the edge of the second through hole. In this embodiment, a total of eight second through holes and an annular portion are formed in the insulating plate. The eight second through holes and the annular portion are spaced apart from each other in the y direction. A total of eight second through holes and annular portions are arranged in one row and eight columns with the x and y directions as matrix directions.

<2nd N bus bar>
The second N bus bar 142 is manufactured by pressing a metal flat plate. The second N bus bar 142 has a second electrode portion.

As shown in FIG. 27, a portion of the second N bus bar 142 is exposed from the front surface 441a of the main body portion 441. The entire second electrode section is housed in the main body section 441.

The portion of the second N bus bar 142 exposed from the front surface 441a has a second upper surface and a second lower surface that are aligned in the z direction. Although not shown, a third through hole and a fourth through hole are formed in the exposed portion of the second N bus bar 142 so as to penetrate through the second upper surface and the second lower surface. As shown in FIG. 27 as a third through hole formation range and a fourth through hole formation range, the third through hole is located closer to the second electrode part in the x direction than the fourth through hole.

In this embodiment, a total of eight third through holes and a total of eight fourth through holes are formed in the exposed portion of the second N bus bar 142. The eight third through holes are spaced apart from each other in the y direction. The eight fourth through holes are also spaced apart from each other in the y direction. These eight third through holes and eight fourth through holes are spaced apart from each other in the x direction. A total of 16 through holes are arranged in 2 rows and 8 columns with the x and y directions as matrix directions.

Although not shown, the exposed portion of the second N bus bar 142 is integrally connected with a second connecting portion that stands up in the z direction from the annular side surface that partitions the fourth through hole toward the bottom of the second lower surface. has been done. In this embodiment, a total of eight second connection parts are spaced apart and lined up in the y direction.

Although not shown, the second electrode portion has a longer length in the y direction than the exposed portion of the second N bus bar 142. A portion of the second electrode section that extends in the y direction including a connection portion with the exposed portion of the second N bus bar 142 is a second connection portion, and a portion that includes a portion of the second electrode portion that is not connected with the exposed portion of the second N bus bar 142. The portion extending in the y direction is the second unconnected portion. One second connected portion and one second unconnected portion are connected in line in the y direction. The creepage distance between the second connecting portion and the second connecting portion is shorter than the creeping distance between the second unconnected portion and the second connecting portion.

<Stacked arrangement>
The exposed portion of the third P bus bar 133 and the exposed portion of the second N bus bar 142 are stacked in the z direction with an insulating plate interposed therebetween. The insulating plate is provided in the z-direction projection area of the exposed portion of the third P bus bar 133 in the exposed portion of the second N bus bar 142 . The insulating plate is not provided in the non-projection area of the exposed portion of the third P bus bar 133 in the exposed portion of the second N bus bar 142 . The formation region of the fourth through hole in the exposed portion of the second N bus bar 142 is a non-projection region of the exposed portion of the third P bus bar 133.

This stacked arrangement allows the first through hole, the second through hole, and the third through hole to communicate in the z direction. The first connecting portion connected to the first through hole projects to the lower side of the exposed portion of the second N bus bar 142 via the second through hole and the third through hole. At the same time, the annular portion formed around the edge of the second through hole protrudes below the exposed portion of the second N bus bar 142 via the third through hole. This annular portion is interposed between the first connecting portion and the edge defining the third through hole. Then, the first connecting portion and the second connecting portion are lined up in the x direction. A total of 16 connections are arranged in 2 rows and 8 columns with the x and y directions as matrix directions.

<Connection form>
A switch module 270 is provided above the third P bus bar 133. The collector terminal 295 of this switch module 270 is passed through the third through hole, the second through hole, and the first through hole. The tip of the collector terminal 295 protrudes below the second lower surface of the exposed portion of the second N bus bar 142 in the z direction. The tip of the collector terminal 295 and the first connecting portion are joined by laser irradiation in such a manner that they face each other in the y direction. Thereby, the collector terminal 295 is electrically connected to the third P bus bar 133.

Further, the emitter terminal 296 of the switch module 270 is passed through the fourth through hole. The tip of the emitter terminal 296 protrudes below the second lower surface of the exposed portion of the second N bus bar 142 in the z direction. The tip of the emitter terminal 296 and the second connection portion are joined by laser irradiation in such a manner that they face each other in the y direction. This electrically connects the emitter terminal 296 to the second N bus bar 142.

Note that an example is shown in which the number of each of the first through hole and the first connecting portion, the second through hole and the annular portion, the third through hole, and the fourth through hole and the second connecting portion is eight. That is, an example has been shown in which the number of holes, connection parts, and annular parts is the same as the number of collector terminals 295 and emitter terminals 296 included in the switch module 270. However, the number of holes, connecting portions, and annular portions may be greater than the number of collector terminals 295 and emitter terminals 296.

<Busbar module>
Next, the bus bar case 450 will be explained based on FIGS. 29 to 34. The busbar case 450 is made of an insulating resin material. The second P bus bar 132, the phase bus bar 150, and the current sensor 233 are housed in the bus bar case 450. This constitutes a bus bar module.

<Busba case>
The bus bar case 450 has a base portion 451, a flange portion 452, and a connector portion 453, to be described in detail. These base portion 451, flange portion 452, and connector portion 453 are each integrally connected by a resin material that constitutes busbar case 450.

As shown in FIGS. 29 and 30, the base 451 has a substantially rectangular parallelepiped shape with its longitudinal direction in the y direction. For this purpose, the base 451 has a front surface 451a and a rear surface 451b arranged in the x direction, a left surface 451c and a right surface 451d arranged in the y direction, and an upper surface 451e and a lower surface 451f arranged in the z direction.

As shown in FIGS. 29 and 32 or 31 and 33, a flange portion 452 is integrally connected to a left surface 451c and a right surface 451d of the base portion 451, respectively. One of these two flange portions 452 projects in the y direction in a manner that is spaced apart from the left surface 451c. The other of the two flange portions 452 protrudes in the y direction so as to be spaced apart from the right surface 451d.

Further, a flange portion 452 is integrally connected to the rear surface 451b of the base portion 451. This flange portion 452 extends in the x direction.

Metal collars 452a are insert-molded into these three flange portions 452. The collar 452a has an annular shape opening in the z direction. A bolt is passed through the hollow of this collar 452a. The tip side of this bolt is fastened to the upper housing 520. This fixes the busbar case 450 to the upper housing 520.

As shown in FIGS. 29 and 30, three connector parts 453 are connected to the upper surface 451e of the base 451. The connector portion 453 extends in the z direction so as to be spaced apart from the upper surface 451e.

A plurality of current detection terminals 236 are housed in the connector portion 453. Current detection terminal 236 extends in the z direction. The tip of the current detection terminal 236 is exposed from the connector portion 453. The tip of this current detection terminal 236 is connected to the control board 240.

<Second P bus bar and companion bus bar>
As shown in FIGS. 29 and 30, the second P bus bar 132 and the U1 phase bus bar 151 to W2 phase bus bar 156 are insert-molded in the base 451. One end 150a of these seven bus bars is exposed from the front surface 451a.

One ends 150a of the U1 phase bus bar 151 to the W2 phase bus bar 156 are spaced apart from each other in the y direction. The second P bus bar 132 is spaced apart from these six bus bars in the z direction.

One end 150a of these seven bus bars has a flat plate shape with a thin thickness in the x direction. A hole 150c penetrating in the x direction is formed in one end 150a of these seven bus bars.

One end 150a of the U1 phase bus bar 151 to W2 phase bus bar 156 is arranged to face the front surface 451a in the x direction. Bolt holes are formed in the base 451 to correspond to holes 150c formed in one ends 150a of these six bus bars. Terminals of the power wire harness 120 are bolted to these two holes communicating in the x direction.

One end 150a of the second P bus bar 132 is not opposed to the front surface 451a in the x direction. An end portion of a second relay bus bar 262 is arranged to face this one end 150a in the x direction. This second relay bus bar 262 also has a hole penetrating in the x direction. The second P bus bar 132 and the second relay bus bar 262 are bolted together. Thereby, reactor 260 and second P bus bar 132 are electrically connected.

As shown in FIGS. 32 and 34, the other ends 150b of the second P bus bar 132 and the U1 phase bus bar 151 to W2 phase bus bar 156 protrude from the rear surface 451b. The other ends 150b of these seven bus bars are spaced apart from each other in the y direction. The other end 150b is lined up in the order of the second P bus bar 132 and the U1 phase bus bar 151 to W2 phase bus bar 156 from the left surface 451c toward the right surface 451d.

The other ends 150b of the U1 phase bus bar 151 to W2 phase bus bar 156 have a flat shape with a thin thickness in the y direction. The connecting surface of the other end 150b facing the y direction and the output terminals 297 of the U1 phase switch module 273 to W2 phase switch module 278 are arranged in contact with each other so as to face each other in the y direction. The other end 150b and the output terminal 297 are irradiated with a laser. As a result, the U1 phase bus bar 151 to W2 phase bus bar 156 and the output terminal 297 are welded together.

As shown in FIGS. 29 and 34, the other end 150b of the second P bus bar 132 is bifurcated. Each of these bifurcated parts has a flat shape with a thin thickness in the y direction. The connecting surface of this bifurcated portion facing the y direction and the output terminals 297 of the A-phase switch module 271 and the B-phase switch module 272 are arranged in contact with each other so as to face each other in the y-direction. The bifurcated portion and the output terminal 297 are irradiated with a laser beam. Thereby, the second P bus bar 132 and the output terminal 297 are welded together.

<Control board>
As described above, the control board 240 has the upper wiring board 245 shown in FIG. A plurality of through holes 246 penetrating in the z direction are formed in this upper wiring board 245. A gate terminal 298, a temperature detection terminal 235, a voltage detection terminal 234, and a current detection terminal 236 are inserted into these plurality of through holes 246, respectively.

As described above, the switch module 270 including the gate terminal 298 and the temperature detection terminal 235, the capacitor case 440 in which the voltage detection terminal 234 is provided, and the busbar case 450 in which the current detection terminal 236 is provided, in the x direction and y direction, respectively. The position of the direction is different. Therefore, the positions of the through holes 246 to which the gate terminal 298, the temperature detection terminal 235, the voltage detection terminal 234, and the current detection terminal 236 are connected are also different in the x direction and the y direction.

In the following, to simplify the explanation, the plurality of through holes 246 to which the gate terminal 298 and the temperature detection terminal 235 are connected will be referred to as a first through hole group 246a. The plurality of through holes 246 to which the voltage detection terminals 234 are connected are referred to as a second through hole group 246b. The plurality of through holes 246 to which the current detection terminals 236 are connected are referred to as a third through hole group 246c. In the drawing, these three are shown surrounded by broken lines.

As shown in FIG. 14, a first through hole group 246a, a second through hole group 246b, and a third through hole group 246c are formed on the upper wiring board 245 so as to be spaced apart in the x direction.

As shown in FIG. 16, the second through hole group 246b is located on the rear upper wall 524 side in the x direction. The third through hole group 246c is located on the front upper wall 523 side in the x direction. The position of the first through hole group 246a in the x direction is between the second through hole group 246b and the third through hole group 246c.

<Number of through holes included per unit area>
As shown in FIG. 14, the number of through holes 246 included in the first through hole group 246a per unit area is greater than the number of through holes 246 per unit area included in the second through hole group 246b. There is. The number of through holes 246 per unit area included in the first through hole group 246a is greater than the number of through holes 246 per unit area included in the third through hole group 246c.

The guide portion and fixing portion described above are provided for the second through hole group 246b and the third through hole group 246c, which have a smaller number of through holes 246 per unit area than the first through hole group 246a.

(Other variations)
In this embodiment, an example is shown in which the power conversion device 30 includes a converter 210 and an inverter 220. However, power converter 30 may include only one of converter 210 and inverter 220.

In this embodiment, the power converter 30 has an example in which the DC/DC converter 330 is provided. However, the power converter 30 does not have to include the DCDC converter 330.

In this embodiment, an example is shown in which the power conversion device 30 is included in the in-vehicle system 100 for an electric vehicle. However, the application of the power conversion device 30 is not particularly limited to the above example. For example, a configuration in which the power conversion device 30 is included in a hybrid system including the motor 40 and an internal combustion engine can also be adopted.

In this embodiment, an example was shown in which the motor 40 includes two first MGs 41 and second MGs 42. However, it is also possible to employ a configuration in which the motor 40 has a single MG. In this case, the inverter 220 of the power conversion device 30 has a switch module of at least three phases.

In this embodiment, an example is shown in which eight switch modules are housed in the cooler 430. However, for example, the cooler 430 may house ten or seven switch modules.

In this embodiment, an example has been shown in which the high side switch 291, the low side switch 292, and the high side diode 293 and the low side diode 294 are each covered with one coating resin 600 to form one switch module.

However, different from this, for example, the high side switch 291 and the high side diode 293 may be covered with one coating resin 600 to form one switch module. The low side switch 292 and the low side diode 294 may be covered with one coating resin 600 to form one switch module. The form of the switch module is not particularly limited.

In this embodiment, bolting or the like is shown as a connection method between a plurality of parts. However, various connection methods can be used to connect the plurality of components as long as they do not cause any particular problems. Various connection methods include, for example, mechanical joining using bolts, screws, springs, and rivets, and metallurgical joining such as welding and brazing.

Although the present disclosure has been described based on examples, it is understood that the present disclosure is not limited to the examples or structures. The present disclosure also includes various modifications and equivalent modifications. In addition, although various combinations and configurations are shown in this disclosure, other combinations and configurations that include only one element, more, or less elements also fall within the scope and spirit of this disclosure. It is something.

DESCRIPTION OF SYMBOLS 10...Battery, 30...Power conversion device, 40...Motor, 100...In-vehicle system, 130...P bus bar, 131...1st P bus bar, 132...2nd P bus bar, 133...3rd P bus bar, 140...N bus bar, 141...th 1N bus bar, 142...2nd N bus bar, 271...A phase switch module, 272...B phase switch module, 273...U1 phase switch module, 274...V1 phase switch module, 275...W1 phase switch module, 276...U2 phase switch module , 277...V 2-phase switch module, 278...W 2-phase switch module, 295...emitter terminal, 296...collector terminal, 310...smoothing capacitor

Claims (1)

A plurality of switch modules (271 to 278) lined up in the arrangement direction,
bus bars (133, 142) connected to connection terminals (295, 296) of each of the plurality of switch modules;
a capacitor (310) connected to each of the plurality of switch modules via the bus bar;
The bus bar has a larger number of connection parts than the connection terminals,
A power conversion device in which all of the plurality of connection terminals are connected to a part of the plurality of connection parts.

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