JP5626158B2 - Power converter - Google Patents

Description

  The present invention relates to a power conversion device including a semiconductor module constituting a power conversion circuit, a cooling means thereof, and the like.

There is known a power conversion device that is mounted on an electric vehicle, a hybrid vehicle, or the like and performs power conversion between DC power and AC power (see Patent Document 1).
As the power conversion device, for example, as shown in FIG. 6, a plurality of semiconductor modules 921 incorporating semiconductor elements and a plurality of cooling pipes (refrigerant flow paths) 922 for circulating a coolant for cooling the semiconductor modules 921 are stacked. A reactor 95 having a laminated body 92, a cylindrical coil (not shown) that generates a magnetic flux when energized, and a core 952 that is made of a magnetic powder mixed resin obtained by mixing a magnetic powder in a resin and in which the coil is embedded. There is a power converter 91 provided with.

  As shown in the figure, the coil of the reactor 95 includes a winding portion (not shown) formed by winding a conductor wire, and a pair of conductor wires taken out from the winding portion and partially protruding from the core 952. A take-out portion 951. Of the pair of extraction units 951, one extraction unit 951 is connected to the power terminal 923 of the semiconductor module 921 that forms part of the booster circuit of the power conversion circuit via the bus bar 96. The other extraction portion 951 is connected to a capacitor or the like via a bus bar (not shown).

JP 2010-118423 A

However, the power converter 91 having the above structure has the following problems.
That is, as shown in FIG. 6, the pair of extraction portions 951 of the coil are arranged close to each other on one end side in the orthogonal direction Y orthogonal to both the lamination direction X of the laminated body 92 and the protruding direction of the extraction portion 951. Has been. Therefore, when the reactor 95 mounted on the right-hand drive power conversion device 91 as shown in FIG. 6 is applied to the left-hand drive power conversion device 91 having a symmetrical shape and structure as shown in FIG. The positional relationship between the pair of coil extraction portions 951 and the laminated body 92 is greatly different.

  For this reason, there arises a problem that the length, shape, and the like of the bus bar 96 that connects between one extraction portion 951 of the coil and the power terminal 923 of the semiconductor module 921 must be significantly changed. For example, as shown in FIG. 7, if the distance between one extraction portion 951 and the power terminal 923 of the semiconductor module 921 connected to the extraction portion 951 is increased, the bus bar 96 must be increased. As a result, problems such as an increase in cost and an increase in heat generation occur.

  This invention is made | formed in view of this background, and it is going to provide the power converter device which can aim at the simplification of a manufacturing process and the improvement of manufacturing efficiency while being excellent in the mounting property of a reactor. .

One aspect of the present invention is a laminated body formed by laminating a plurality of semiconductor module parts incorporating semiconductor elements and a plurality of refrigerant flow paths for circulating a refrigerant for cooling the semiconductor module parts,
A reactor having a cylindrical coil that generates a magnetic flux when energized, and a core made of a magnetic powder mixed resin obtained by mixing magnetic powder in a resin and having the coil embedded therein;
The reactor is arranged on one end side in the stacking direction of the stacked body,
The coil of the reactor includes a winding portion formed by winding a conductor wire, and a pair of extraction portions formed by taking out the conductor wire from the winding portion and projecting a part thereof in the same direction from the core. Have
Each of the semiconductor module parts of the laminate is provided with a plurality of power terminals protruding in the same direction as the extraction part,
In the laminated body, a plurality of terminal rows composed of a plurality of the power terminals arranged substantially linearly in the laminating direction are arranged in an orthogonal direction perpendicular to both the laminating direction and the protruding direction of the extraction portion. Formed,
The pair of lead-out portions of the coil are disposed at both ends of the core in the orthogonal direction, and are disposed so as to be substantially linear with respect to the different terminal rows of the laminate,
Either one of the pair of extraction parts is connected to a predetermined power terminal in a part of the semiconductor module part via a bus bar,
The bus bar has an extraction connection portion connected to the extraction portion, a terminal connection portion connected to the power terminal, and a connecting portion connecting between the extraction connection portion and the terminal connection portion,
The connecting portion is formed in the stacking direction so as to pass outside of the plurality of terminal rows in the orthogonal direction (claim 1).

In the power converter, a reactor is disposed on one end side in the stacking direction of the stacked body. Moreover, the coil of the reactor has a winding part formed by winding a conductor wire, and a pair of extraction parts formed by taking out the conductor wire from the winding part and projecting a part thereof from the core. And a pair of extraction part of a coil is arrange | positioned at the both ends of the orthogonal direction of a core.
Therefore, for example, even if a reactor mounted on a right-hand drive power conversion device is applied to a left-hand drive power conversion device having a symmetrical shape and structure, the positional relationship between the pair of coil extraction parts and the laminate The reactor can be installed without greatly changing the.

  That is, for example, if a reactor mounted on a right-hand drive power conversion device is mounted on a left-hand drive power conversion device with its orthogonal direction reversed, the pair of coil take-out portions are similarly It is arrange | positioned at the both ends of an orthogonal direction, and the positional relationship of a pair of extraction part of a coil and a laminated body is not changed greatly (refer FIG. 1, FIG. 4 of the Example mentioned later). Therefore, when the main body of the bus bar is arranged on the same side in the orthogonal direction in the right handle specification and the left handle specification, it is not necessary to greatly change the length, shape, etc. of the bus bar. As a result, it is possible to suppress an increase in cost, an increase in heat generation, and the like due to a significant change in the length, shape, and the like of the bus bar as in the past, and the reactor can be easily mounted.

  Further, the pair of extraction portions of the coil are arranged so as to be substantially linear with respect to the different terminal rows of the laminate. Therefore, the welding of the power terminals forming the terminal row of the laminate and the bus bar connected thereto and the welding of the coil extraction portion and the bus bar connected thereto can be continuously performed in the laminating direction. Thereby, a welding process can be performed easily and efficiently, a manufacturing process can be simplified and manufacturing efficiency can be improved.

  As described above, it is possible to provide a power converter that is excellent in the mountability of the reactor, can simplify the manufacturing process, and can improve the manufacturing efficiency.

Explanatory drawing which shows the power converter device of the right handle | steering-wheel specification which mounts the reactor in an Example. The top view which shows the reactor in an Example. The perspective view which shows the reactor in an Example. Explanatory drawing which shows the power converter device of the left handle | steering-wheel specification which mounts the reactor in an Example. The top view which shows the reactor of another example in an Example. Explanatory drawing which shows the power converter device of the right handle | steering-wheel specification which mounts the reactor in background art. Explanatory drawing which shows the power converter device of the left handle specification which mounts the reactor in background art.

In the power conversion apparatus, the semiconductor module unit can be configured by one or a plurality of semiconductor modules incorporating a semiconductor element.
Moreover, as an external shape of the said winding part of the said coil, circular shape, an oval shape, etc. are employable, for example.

Further, the pair of extraction portions of the coil may be configured such that the distance from the outer end position of the core in the orthogonal direction is substantially the same (Claim 2).
In this case, for example, if the reactor mounted on the right-hand drive power conversion device is mounted on the left-handle power conversion device with the direction of the orthogonal direction reversed, the pair of coil extraction parts and the laminate It is possible to make the change in the positional relationship between and very small. In particular, the positions of the pair of extraction portions in the orthogonal direction can be made substantially the same. Thereby, the mountability of a reactor can further be improved.

Further, the pair of extraction portions of the coil can be configured to be disposed substantially opposite to each other in the orthogonal direction (Claim 3).
In this case, for example, if the reactor mounted on the right-hand drive power conversion device is mounted on the left-handle power conversion device with the direction of the orthogonal direction reversed, the pair of coil extraction parts and the laminate It is possible to make the change in the positional relationship between and very small. In particular, the positions of the pair of extraction portions in the stacking direction can be made substantially the same. Thereby, the mountability of a reactor can further be improved.
In addition, the substantially opposed position in the orthogonal direction refers to a position facing in the orthogonal direction or a position facing in a direction close to the orthogonal direction (position close to the position facing in the orthogonal direction).

Further, the pair of extraction portions of the coil can be arranged at the end of the core on the laminated body side (claim 4).
In this case, the distance between one extraction part of the coil and the power terminal of the semiconductor module part of the stacked body to which the extraction part is connected via the bus bar can be shortened. Thereby, the length of a bus bar can be shortened and the heat_generation | fever of a bus bar can be suppressed.
In addition, the edge part by the side of the laminated body of the said core means the part of the laminated body side rather than the intermediate position of the lamination direction in a core.

An embodiment according to a power conversion device will be described with reference to the drawings.
As shown in FIGS. 1 to 3, the power conversion device 1 of the present example includes a plurality of semiconductor module units 20 incorporating semiconductor elements, and a plurality of cooling pipes (refrigerant flow paths) through which a refrigerant that cools the semiconductor module unit 20 flows. ) 22, a cylindrical coil 51 that generates magnetic flux when energized, and a magnetic powder mixed resin in which magnetic powder is mixed with resin, and a core that is embedded in the coil 51. And a reactor 5 having 52.

A reactor 5 is disposed on one end side in the stacking direction X of the stacked body 2. The coil 51 of the reactor 5 includes a winding portion 511 formed by winding a conductor wire 510 and a pair of take-outs in which the conductor wire 510 is taken out from the winding portion 511 and a part thereof protrudes from the core 52 in the same direction. Part 512.
Each semiconductor module part 20 of the stacked body 2 is provided with a plurality of power terminals 211 that protrude in the same direction as the extraction part 512. In the stacked body 2, a terminal row 29 composed of a plurality of power terminals 211 arranged substantially linearly in the stacking direction X has an orthogonal direction Y orthogonal to both the stacking direction X and the protruding direction of the extraction portion 512. A plurality are formed.

The pair of extraction portions 512 of the coil 51 are arranged at both ends in the orthogonal direction Y of the core 52 and are arranged so as to be substantially linear with respect to the different terminal rows 29 of the laminate 2. One of the pair of extraction parts 512 is connected to a predetermined power terminal 211 in a part of the semiconductor module parts 20 via the bus bar 6.
The bus bar 6 includes an extraction connection portion 61 connected to the extraction portion 512, a terminal connection portion 62 connected to the power terminal 211, and a connecting portion 63 that connects the extraction connection portion 61 and the terminal connection portion 62. . The connecting portion 63 is formed in the stacking direction X so as to pass outside the plurality of terminal rows 29 in the orthogonal direction Y. Hereinafter, this will be described in detail.

As shown in FIG. 1, the power conversion device 1 of this example is mounted on an electric vehicle, a hybrid vehicle, or the like, performs power conversion between DC power and AC power, and has a right-hand drive specification.
In the power conversion device 1, the stacked body 2 is formed by alternately stacking a plurality of semiconductor module units 20 and a plurality of cooling pipes 22.
Each semiconductor module unit 20 includes two semiconductor modules 21 and is sandwiched by cooling pipes 22 from both sides in the stacking direction X. The semiconductor module 21 incorporates a switching element such as IGBT and a diode such as FWD (not shown).

  The plurality of cooling pipes 22 are connected at both ends in the longitudinal direction (orthogonal direction Y) by connecting pipes 23 in which adjacent cooling pipes 22 can be deformed. In addition, a refrigerant introduction pipe 24 that introduces a refrigerant from the outside and a refrigerant discharge pipe 25 that discharges the refrigerant to the outside are connected to both ends of the cooling pipe 22 disposed at the front end in the stacking direction X. A part of the refrigerant introduction pipe 24 and the refrigerant discharge pipe 25 protrudes outside the frame 4.

  The refrigerant introduced from the refrigerant introduction pipe 24 passes through the connection pipe 23 on the refrigerant introduction pipe 24 side, is distributed to each cooling pipe 22 and circulates in the longitudinal direction (orthogonal direction Y). The refrigerant exchanges heat with the semiconductor module 21 while flowing through the cooling pipes 22. The refrigerant whose temperature has increased due to heat exchange passes through the connecting pipe 23 on the refrigerant discharge pipe 25 side and is discharged from the refrigerant discharge pipe 25 as appropriate.

  Examples of the refrigerant circulating in the cooling pipe 22 and the like include natural refrigerants such as water and ammonia, water mixed with ethylene glycol antifreeze, fluorocarbon refrigerants such as fluorinate, and chlorofluorocarbon refrigerants such as HCFC123 and HFC134a. A refrigerant such as alcohol refrigerant such as methanol or alcohol, or a ketone refrigerant such as acetone can be used.

Moreover, as shown in the figure, each semiconductor module part 20 of the laminated body 2 is provided with four power terminals 211 (211a to 211d) projecting in the same direction as the extraction part 512 of the coil 51 of the reactor 5 described later. It has been.
In the stacked body 2, four terminal rows 29 (29 a to 29 d) composed of a plurality of power terminals 211 (211 a to 211 d) arranged in a substantially straight line in the stacking direction X are aligned in the orthogonal direction Y. Is formed.

A reactor 5 is disposed on one end side of the stacked body 2. One end of the stacked body 2 is in contact with the case 54 of the reactor 1.
Further, on the other end side of the laminate 2, an elastic member 31 that is a flat plate spring, a pair of support pins 32 that support the elastic member 31, and the elastic member 31 and the laminate 2 are disposed. A pressure member 3 including the contact plate 33 is disposed. The pair of support pins 32 are disposed between both end portions of the elastic member 31 and the frame 4 described later.

Moreover, the laminated body 2, the pressurizing member 3, and the reactor 5 are accommodated inside the frame 4 formed so as to surround the laminated body 2 from four directions.
Further, the elastic member 31 of the pressing member 3 is sandwiched between the contact plate 33 in contact with the stacked body 2 and the support pin 32 in a state of being elastically deformed in the stacking direction X. Further, the elastic member 31 presses the stacked body 2 via the contact plate 33. Thereby, the laminated body 2 is held in the frame 4 in a state of being pressurized (compressed) in the laminating direction X by the urging force of the elastic member 31.

As shown in FIGS. 2 and 3, the reactor 5 includes a coil 51 that generates a magnetic flux when energized, and a core 52 that forms a magnetic path of the magnetic flux generated when the coil 51 is energized.
The coil 51 has a cylindrical winding portion 511 formed by spirally winding a conductor wire 510 made of copper wire, and a pair of extraction portions 512 formed by taking out the conductor wire 510 from the winding portion 511. The outer shape of the winding part 511 is an oval shape. The coil 51 is embedded in the core 52, and a part of the pair of extraction portions 512 is protruded from the core 52 in the same direction.
The core 52 is made of a magnetic powder mixed resin obtained by mixing an epoxy resin as an insulating resin with iron powder as a magnetic powder. The core 52 is disposed so as to cover the entire coil 51.

As shown in the drawing, on the inner peripheral side of the coil 51, a cylindrical core member 53 for transmitting and releasing heat generated in the coil 51 and the core 52 and fixing the reactor 5 is disposed. ing.
The coil 51, the core 52, and the core member 53 are accommodated inside a case 54 having a bottomed box shape. A core member 53 is fixed to the case 54. The opening 541 of the case 54 is not illustrated, but is closed by a plate-shaped lid.

As shown in FIG. 1, the pair of extraction portions 512 of the coil 51 are disposed at both ends of the core 52 in the orthogonal direction Y.
As shown in FIG. 2, the pair of extraction portions 512 have the same distance from the outer end position A in the orthogonal direction Y of the core 52. In this example, the pair of extraction portions 512 have the same distances L <b> 1 and L <b> 2 from the outer end position A in the orthogonal direction Y of the core 52, that is, from both end surfaces 521 and 522 in the orthogonal direction Y of the core 52.

As shown in FIG. 1, the pair of extraction portions 512 of the coil 51 is disposed at the end of the core 52 on the laminated body 2 side. That is, the core 52 is disposed at a portion closer to the stacked body 2 than the intermediate position in the stacking direction X.
The pair of extraction portions 512 are arranged so as to be linear with respect to the different terminal rows 29 (29 a to 29 d) of the stacked body 2. In this example, one extraction part 512 is arranged linearly with respect to the terminal row 29a. The other extraction portion 512 is arranged so as to be linear with respect to the terminal row 29d.

As shown in the figure, of the pair of extraction sections 512 of the coil 51, one extraction section 512 is a part of the semiconductor module section 20 (semiconductor module 21) that constitutes the booster circuit of the power conversion circuit via the bus bar 6. Are connected to the power terminals 211a and 211d.
Further, the other extraction portion 512 is connected to a capacitor or the like via a bus bar (not shown).

The bus bar 6 includes an extraction connection portion 61 connected to one extraction portion 512 of the coil 51 of the reactor 5, and a terminal connection portion 62 connected to a power terminal 211 of a part of the semiconductor module portion 20 (semiconductor module 21). And a connecting portion 63 that connects between the take-out connecting portion 61 and the terminal connecting portion 62.
The connecting portion 63 is formed in the stacking direction X so as to pass outside the plurality of terminal rows 29 in the orthogonal direction Y. Further, the extraction connecting portion 61 and the terminal connecting portion 62 are formed in the orthogonal direction Y from both ends of the connecting portion 63 in the stacking direction X.

Next, the effect in the power converter device 1 of this example is demonstrated.
In the power conversion device 1 of this example, a reactor 5 is disposed on one end side in the stacking direction X of the stacked body 2. Further, the coil 51 of the reactor 5 includes a winding portion 511 formed by winding the conductor wire 510 and a pair of extraction portions formed by taking out the conductor wire 510 from the winding portion 511 and partially protruding from the core 52. 512. The pair of extraction portions 512 of the coil 51 are disposed at both ends of the core 52 in the orthogonal direction Y.
Therefore, even when the reactor 5 mounted on the right-hand drive power conversion device 1 (FIG. 1) is applied to the left-hand drive power conversion device 1 having a symmetrical shape and structure as shown in FIG. The reactor 5 can be mounted without greatly changing the positional relationship between the pair of 51 extraction portions 512 and the stacked body 2.

  That is, if the reactor 5 mounted on the right-hand drive power conversion device 1 (FIG. 1) is mounted on the left-hand drive power conversion device 1 with its orthogonal direction Y reversed as shown in FIG. Similarly, the pair of extraction portions 512 of the coil 51 are disposed at both ends of the core 52 in the orthogonal direction Y, and the positional relationship between the pair of extraction portions 512 of the coil 51 and the laminate 2 is not significantly changed. Therefore, when the connecting portion 63 of the bus bar 6 is arranged on the same side in the orthogonal direction Y in the right handle specification and the left handle specification, it is not necessary to greatly change the length, shape, etc. of the bus bar 6. Thereby, it is possible to suppress an increase in cost, an increase in heat generation, and the like due to a significant change in the length and shape of the bus bar 6 as in the conventional case, and the reactor 5 is excellent in mountability.

  Further, the pair of extraction portions 512 of the coil 5 are arranged so as to be substantially linear with respect to the different terminal rows 29 of the laminate 2. Therefore, welding of the power terminals 211 forming the terminal row 29 of the laminate 2 and the bus bars (including the bus bar 6) connected thereto and the extraction part 512 of the coil 51 and the bus bars (including the bus bar 6) connected thereto. And the like can be continuously performed in the stacking direction X. Thereby, a welding process can be performed easily and efficiently, a manufacturing process can be simplified and manufacturing efficiency can be improved.

  Further, in this example, the pair of extraction portions 512 of the coil 51 have the same distances L1 and L2 from the outer end position A in the orthogonal direction Y of the core 52. Therefore, if the reactor 5 mounted on the right-hand drive power conversion device 1 (FIG. 1) is mounted on the left-handle power conversion device 1 with its orthogonal direction Y reversed as shown in FIG. The change in the positional relationship between the pair of extraction portions 512 of the coil 5 and the laminate 2 can be made extremely small. In particular, the position in the orthogonal direction Y of a pair of extraction part 512 can be made the same. Thereby, the mountability of the reactor 5 can further be improved.

  In addition, the pair of extraction portions 512 of the coil 51 is disposed at the end portion of the core 52 on the laminated body 2 side. Therefore, the distance between the one extraction part 512 of the coil 51 and the power terminal 211 of the semiconductor module part 20 (semiconductor module 21) of the stacked body 2 to which the extraction part 512 is connected via the bus bar 6 is shortened. Can do. Thereby, the length of the bus bar 6 (connection part 63) can be shortened, and the heat_generation | fever of the bus bar 6 can be suppressed.

  Thus, according to the present example, it is possible to provide the power conversion device 1 that is excellent in the mountability of the reactor 5 and that can simplify the manufacturing process and improve the manufacturing efficiency.

Further, in this example, the pair of extraction portions 512 of the coil 51 in the reactor 5 are arranged at positions slightly shifted in the stacking direction X as shown in FIGS. 1 and 2, but are orthogonal as shown in FIG. It can also be arranged facing in the direction Y.
In this case, for example, the reactor 5 mounted on the right-hand drive power conversion device 1 (FIG. 1) is mounted on the left-handle power conversion device 1 (FIG. 4) with the direction of the orthogonal direction Y reversed. If it does so, the change of the positional relationship of a pair of extraction part 512 of the coil 5 and the laminated body 2 can be made very small. In particular, the positions of the pair of extraction portions 512 in the stacking direction X can be the same. Thereby, the mountability of the reactor 5 can further be improved.

DESCRIPTION OF SYMBOLS 1 Power converter 2 Laminate 20 Semiconductor module part 211 Power terminal 22 Cooling pipe (refrigerant flow path)
29 Terminal row 5 Reactor 51 Coil 511 Winding part 512 Extraction part 52 Core 6 Bus bar 61 Extraction connection part 62 Terminal connection part 63 Connection part X Stacking direction Y Orthogonal direction

Claims (4)

A laminated body formed by laminating a plurality of semiconductor module portions each including a semiconductor element, and a plurality of refrigerant flow paths for circulating a refrigerant for cooling the semiconductor module portions;
A reactor having a cylindrical coil that generates a magnetic flux when energized, and a core made of a magnetic powder mixed resin obtained by mixing magnetic powder in a resin and having the coil embedded therein;
The reactor is arranged on one end side in the stacking direction of the stacked body,
The coil of the reactor includes a winding portion formed by winding a conductor wire, and a pair of extraction portions formed by taking out the conductor wire from the winding portion and projecting a part thereof in the same direction from the core. Have
Each of the semiconductor module parts of the laminate is provided with a plurality of power terminals protruding in the same direction as the extraction part,
In the laminated body, a plurality of terminal rows composed of a plurality of the power terminals arranged substantially linearly in the laminating direction are arranged in an orthogonal direction perpendicular to both the laminating direction and the protruding direction of the extraction portion. Formed,
The pair of lead-out portions of the coil are disposed at both ends of the core in the orthogonal direction, and are disposed so as to be substantially linear with respect to the different terminal rows of the laminate,
Either one of the pair of extraction parts is connected to a predetermined power terminal in a part of the semiconductor module part via a bus bar,
The bus bar has an extraction connection portion connected to the extraction portion, a terminal connection portion connected to the power terminal, and a connecting portion connecting between the extraction connection portion and the terminal connection portion,
The connecting portion is formed in the stacking direction so as to pass outside the plurality of terminal rows in the orthogonal direction.   2. The power converter according to claim 1, wherein the pair of extraction portions of the coil have substantially the same distance from the outer end position of the core in the orthogonal direction.   3. The power conversion device according to claim 1, wherein the pair of extraction portions of the coil are disposed substantially opposite to each other in the orthogonal direction.   4. The power conversion device according to claim 1, wherein the pair of extraction portions of the coil are arranged at an end of the core on the laminated body side. 5. .

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