JP3731511B2 - Connector integrated power module - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a power module that controls the driving environment of a compressor motor using an inverter circuit in an air conditioner or the like, and in particular, a connection between a power module housing an inverter circuit unit and a compressor motor, and an inverter. The present invention relates to a connection mounting structure of a drive control circuit to a printed wiring board.
[0002]
[Prior art]
A description will be given using a connection configuration diagram of a power module, a control board, and a compressor motor in a conventional air conditioner or the like.
[0003]
In FIG. 1, input / output signal terminals to the power module 10 all have the shape of solder leads 31. Like the other electronic components, the power module is mounted on the control board 40 and then soldered together by an automatic soldering apparatus to facilitate connection between the module and the control board.
[0004]
As the compressor motor, a three-phase brushless motor is generally used, and three connecting cables for each UVW phase are required. The three cables from the compressor motor are gathered by the directional three-pole connector 51, while the three cables output from the power module side are also gathered by the three-pole housing 61 of the conversion cable 60. The connection work between the output line from the compressor and the compressor motor is simplified and misconnection is prevented.
[0005]
FIG. 2 shows a power module in which a general-purpose faston connection terminal 38 for connecting a high voltage and large current line including a compressor motor output is formed, and a soldering lead 31 is integrally formed on the small signal control board 40 side. FIG. 10 is a connection configuration diagram of 10; Unlike the previous FIG. 1, the output to the compressor motor is directly connected to the conversion cable 60 by connecting the faston terminal 38 and the receptacle terminal 65 without relaying the control board. By connecting the wiring between the power module and the compressor motor outside the board, it is not necessary to pass a high-voltage / high-current circuit in the vicinity of the electronic components on the control board that operates at a low voltage, thus preventing malfunction due to noise. . Further, it is not necessary to consider the high-voltage wide pattern that occupies the area of the substrate and the insulation distance, and the substrate can be downsized.
[0006]
FIG. 7 shows a known example (Japanese Patent Laid-Open No. 9-120852) of a semiconductor device in which a connector is built in a case. The power element circuit storage portion 308 and the connector storage portion 309 filled with the potting material 310 are partitioned, and the built-in connector 317 is retrofitted to the molded case, and wire bonding 320 is used for electrical connection between the connector terminal and the power semiconductor element circuit. Therefore, the connector structure portion does not require heat resistance, and a commercially available product can be used. For example, there is an advantage that it is possible to flexibly respond to changes in the connector shape.
[0007]
[Problems to be solved by the invention]
In the example shown in Fig. 1 above, the electrical wiring connection from the power module is completed by mounting the power module on a printed wiring board in the same way as other electronic components, and only by batch soldering using an automatic soldering device. . However, a dedicated fixing plate 70 and screws 71 for fixing the power module main body to the substrate are necessary, and parts and mounting work other than electrical connection are required. In addition, since the output terminal to the compressor motor is also soldered to the board, the connection line to the compressor motor cannot be directly connected to the board, taking into account the workability of assembly into the unit and the serviceability of removal. There is a problem that the number of parts and operations that are not necessary for the original function increase, such as the need for the housing-equipped conversion cable 60 that is soldered to the top.
[0008]
In the example of FIG. 2, the Faston connection terminal is provided for direct output from the power module to the compressor motor. Therefore, the connection cable from the compressor motor can be directly connected to the receptacle terminal shape. Since the number of connections increases and the faston and receptacle shapes are common, there is a possibility of erroneous connection when mounting and dismounting from the unit, and a conversion cable with a housing is still necessary. Further, the lead-shaped portion for soldering in FIGS. 1 and 2 has a required wire diameter of less than 1 mm and a low strength even when the current capacity is taken into consideration. Therefore, it is expected that the pitch between the leads will change due to contact or the like during handling of the power module alone and it will be difficult to insert it into the control board connection hole.
[0009]
In the example of FIG. 7, since a connector is retrofitted to the case after molding and the electrical connection between the connector terminal and the power semiconductor element circuit is wire bonding, there is a disadvantage that the assembly process of the power module increases.
[0010]
An object of the present invention is to reduce the number of connecting wires by hand and the number of parts and man-hours for mounting between an external device such as a compressor motor and a control board and a power module, to save space, and to be an inexpensive connector integrated type. A power module for mounting a printed circuit board is provided.
[0011]
[Means for Solving the Problems]
The above problems are surrounded by a printed wiring board on which a power semiconductor element is mounted using a metal as a base material, a case in which a connector that surrounds the printed wiring board and is connected to an electric motor is integrally formed, and the metal base and the case. A connector-integrated power module comprising: an insulating resin material injected therein; and a mold resin for molding a power supply and a solder lead for supplying the power semiconductor element switching signal in a state separated from the case. Can be achieved.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the actual form of the present invention will be described with reference to FIGS. FIG. 3 is an external view of the invention. The configuration consists of a circuit housing 12 with built-in power semiconductor elements, a lead 31 for soldering connected to an external printed circuit board that supplies power to the power module and a power semiconductor switching signal, and an output connection side to the motor load, etc. It consists of a molded connector shape 34 corresponding to line connection. 4 is an internal cross-sectional view, and FIG. 5 is an external view of a case in which connection terminals are integrally formed.
[0013]
The wiring member that constitutes the circuit housing part is a printed wiring board based on a metal having good thermal conductivity, and the power semiconductor element is bonded to the semiconductor chip and the lead frame, and the resin-encapsulated package molded product is bonded to the substrate. was arranged on the surface, external connection terminals to the apparatus, the lead frame steric molded prewired member Similarly printed wiring board cases insert-mode field molding while positioning the junction of the connection terminal to the bonding surface of the Place on the joint surface. Each is joined by solder.
[0014]
In the assembly process of the power module, an appropriate amount of cream solder is printed on a printed wiring board 20 made of a metal base material at a position necessary for connection. Case 30 in which lead frame is three-dimensionally molded and insert-molded in advance for surface mounting on the printed circuit board connection side and for connection to external devices, and power semiconductor element 24 with leads and resistors / capacitors for surface mounting Components are placed on the board and reflow soldered together.
[0015]
As for the connection terminals to the case and the external device, the output connection side from the power module to the load such as the electric motor has a connector or housing housing structure and terminal shape corresponding to the lead wire connection.
[0016]
Finally the metal base and the inside surrounded by the casing is injected hardening the insulating resin material 11 is completed. Also, the external printed circuit board connection side of the case has a connector shape 31 in which a part of the lead part for mounting solder is molded with resin and separated from the case of the circuit housing part, and a bent shape 33 is provided in the middle part of the lead Form. That is, the external printed circuit board connection side that supplies the power supply to the power module and the power semiconductor switching signal is resin-molded with a part of the mounting solder lead part separated from the case body, and the board mounted connector Form the shape. The purpose of this bent shape 33 is to mount the product of the present invention on an external printed circuit board, after soldering connection, when connecting a connector to a load such as an electric motor, when mounting a power module to a heat radiating fin structure, and by soldering due to thermal shock The main purpose is stress relaxation applied to the attachment. Furthermore, as shown in FIG. 6, the claw shape 36 for positioning and fixing to the board on which the product of the present invention is mounted is not formed on both sides of the mold part on the board connection side, and only the solder joint strength is ensured. A target metal piece 37 is insert-molded inside the claw shape 36. That is, on the external printed circuit board connection side, a metal piece for the purpose of increasing the adhesion and solder joint strength to the substrate mold or the claw shape for fixing the substrate positioning to the resin mold part constituting the connector shape for mounting solder, At least one is integrally formed.
[0017]
【The invention's effect】
The product of the present invention reduces the number of connecting wires by hand and the number of parts and man-hours for mounting between external devices such as compressor motors and control boards and power modules, and saves space and is an inexpensive connector-integrated print. Board mounting power modules can be supplied.
[Brief description of the drawings]
FIG. 1 is a diagram showing an example of connection of a conventional board mounting power module.
FIG. 2 is a diagram showing an example of connecting a power module having a conventional faston terminal.
FIG. 3 is a perspective view of a power module in an embodiment of the present invention.
4 is a diagram showing a cross section of the power module of FIG. 3 and a connection example.
FIG. 5 is a perspective view of only the case of FIG. 3;
6 is an enlarged view of a board fixing claw and a soldering part in FIG. 3;
FIG. 7 is a diagram showing an example of a conventional power module with a built-in connector.
[Explanation of symbols]
10 ... Power module, 11 ... Insulating resin, 12 ... Power element housing, 20 printed circuit board, 24 ... Power semiconductor element, 30 ... Case, 31 ... Board mounting lead, 34 ... Molded connector, 40 ... Control board, 50 ... Compressor connection cable, 60 ... Conversion cable, 70 ... Power module fixing plate.

Claims (3)

  A printed wiring board on which a power semiconductor element is mounted using a metal as a base material, a case in which a connector that surrounds the printed wiring board and is connected to an electric motor, and an interior surrounded by the metal base and the case are injected. A connector-integrated power module comprising: an insulating resin material; and a mold resin for molding a power lead and a solder lead for supplying the power semiconductor element switching signal in a state separated from the case.   The connector-integrated power module according to claim 1, wherein a bent shape is formed in the middle of the lead.   The connector-integrated power module according to claim 1, comprising: a fixed claw for positioning a substrate provided in the mold resin; and a metal piece for solder joining that is insert-molded in the mold resin.

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