JP5971333B2 - 電力変換器 - Google Patents
電力変換器 Download PDFInfo
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- JP5971333B2 JP5971333B2 JP2014509050A JP2014509050A JP5971333B2 JP 5971333 B2 JP5971333 B2 JP 5971333B2 JP 2014509050 A JP2014509050 A JP 2014509050A JP 2014509050 A JP2014509050 A JP 2014509050A JP 5971333 B2 JP5971333 B2 JP 5971333B2
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- insulating layer
- power converter
- metal block
- printed wiring
- wiring board
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Description
前記金属ブロックの下面が前記放熱用絶縁層を介して前記冷却用ヒートシンクの上面に当接するようにして前記電力変換回路組立体が前記冷却用ヒートシンクに取付けられ、
前記パワー半導体ユニットは、前記金属ブロックの上面の一部分に直接セラミックス材料を積層して形成された中継電極用絶縁層と、前記中継電極用絶縁層の上面に金属材料を積層して形成された中継電極とを備え、前記第1の回路素子と前記中継電極とをボンディングワイヤまたはリードフレームにより接続した構成とする(請求項1の発明)。さらに、前記中継電極と前記プリント配線板の上面側の回路パターン部とを、さらにボンディングワイヤまたはリードフレームを介して接続した構成とする(請求項2の発明)。
<第1の実施形態>
図1は本発明の第1の実施形態にかかる電力変換器の構成を示す断面図である。図1において、上面1bおよび下面1aを有する金属ブロック1の上面1bに例えばIGBT(Insulated Gate Bipolar Transistor)などのパワー半導体素子4が実装されてなるパワー半導体ユニット51と、金属ブロック1を収めることが可能な孔27dを有するスルーホール部27が形成されたプリント配線板5に電子回路部品6aが実装されてなるプリント配線板ユニット52とが、金属ブロック1が孔27dにはめ込まれるようにして一体とされ、電力変換回路ユニット53が構成されている。なお、以下では、金属ブロック1の上面1bおよび下面1aをそれぞれ「表面1b」および「裏面1a」とも称する。
(1)絶縁耐圧の向上
エアロゾルデポジション法では、室温(常温)で成膜が可能であり、かつ音速レベルのスピードでサブミクロンオーダーのセラミックス微粒子を基板に衝突させるため、活性な新生面が露出したセラミックス微粒子が結合する。また、プラズマ溶射法によっても同様である。いずれの方法においても、非常にち密な電気絶縁膜であるセラミックス微粒子層を形成することが可能となり、膜内に空孔(ボイド)が含まれないため、従来の焼結法により形成されたセラミックス板よりも単位長さ当たりの破壊電圧が10倍程度向上する。
(2)熱抵抗の低下
熱伝導率はバルクと同等であり、熱伝導率は例えば酸化アルミニウム(Al2O3)で約20W/m・K、窒化アルミニウム(AlN)で約160〜180W/m・K、窒化珪素(Si3N4)で約80W/m・K程度確保できる。これに加えて単位長さ当たりの破壊電圧が向上するため、絶縁層2を薄く形成することができ、このため全体の熱抵抗が低くなる。
<第2の実施形態>
図4は本発明の第2の実施形態にかかる電力変換器の構成を示す断面図である。
第2の実施形態にかかる電力変換器は、上述の第1の実施形態にかかる電力変換器において、特に、上面および下面を有する金属ブロックの上面の一部分に直接セラミックス材料を積層して形成された中継電極用絶縁層と、この中継電極用絶縁層の上面に金属材料を積層して形成された中継電極とを備え、上記金属ブロックの上面に実装されたパワー半導体素子からのボンディングワイヤなどを上記中継電極に接合するとともに、上記中継電極とプリント配線板の回路パターンとをボンディングワイヤなどを介して接続するようにしたものであり、それ以外の点では第1の実施形態にかかる電力変換器と同様である。
1a,1Aa:下面(裏面)
1b,1Ab:上面(表面)
1c,1Ac:側面
2,2A:放熱用絶縁層
3A:中継電極付き金属ブロック
4:パワー半導体素子(第1の回路素子)
5,5A,5B:プリント配線板
6a,6b,6c,6d,6e,6f,6g:電子回路部品(第2の回路素子)
7:冷却用ヒートシンク
7a:上面
8:ケース
9a,9b:プリント配線板
10:パワー半導体モジュール
11:絶縁基板
12:アルミワイヤ
13:切り欠き部
15:金属ベース
16:絶縁層
17:回路パターン
18,18A:接続リード端子
19:絶縁樹脂
20:ケース本体
21:蓋
23,23a,23b:基板本体
24,24a,24b,24c:回路パターン
25,25A:支柱
26:配線
27:スルーホール部
27a:貫通導体部
27b:上面ランド導体部
27c:下面ランド導体部
27d:孔
28a,28b:はんだ
30,30A:マスク
31:原料粉末(セラミックス粉末)
32:銅粒子
41:中継電極
42:中継電極用絶縁層
43a,43b:ボンディングワイヤ
44a,44b:リードフレーム
51,51A,51B:パワー半導体ユニット
52,52A,52B:プリント配線板ユニット
53,53A,53B:電力変換回路ユニット
100,100A,100B,200:電力変換器
501:上面(表面)
502:下面(裏面)
Claims (9)
- 上面および下面を有する金属ブロックの上面にパワー半導体素子からなる第1の回路素子がはんだにより実装されてなるパワー半導体ユニットと、
前記金属ブロックを収めることが可能な孔が明けられたプリント配線板に第2の回路素子が実装されてなるプリント配線板ユニットと、
冷却用ヒートシンクとを備え、
前記金属ブロックが前記孔にはめ込まれるようにして前記パワー半導体ユニットと前記プリント配線板ユニットとが一体とされた電力変換回路組立体が構成されているとともに、
前記冷却用ヒートシンクの上面に直接セラミックス材料が放熱用絶縁層として形成されてなり、
前記金属ブロックの下面が前記放熱用絶縁層を介して前記冷却用ヒートシンクの上面に当接するようにして前記電力変換回路組立体が前記冷却用ヒートシンクに取付けられ、
前記パワー半導体ユニットは、前記金属ブロックの上面の一部分に直接セラミックス材料を積層して形成された中継電極用絶縁層と、前記中継電極用絶縁層の上面に金属材料を積層して形成された中継電極とを備え、
前記第1の回路素子と前記中継電極とをボンディングワイヤまたはリードフレームにより接続したことを特徴とする電力変換器。 - 請求項1に記載の電力変換器において、
前記中継電極と前記プリント配線板の上面側の回路パターン部とを、さらにボンディングワイヤまたはリードフレームを介して接続したことを特徴とする電力変換器。 - 請求項1または2に記載の電力変換器において、
前記孔は、導体層からなるスルーホール部の開口部であって、
前記金属ブロックは、前記スルーホール部にはんだ付で固定されてなり、
前記冷却用ヒートシンクの上面における前記放熱用絶縁層は、前記金属ブロックの下面に当接する領域と前記スルーホール部のランド面に当接する領域とを含むように形成されていることを特徴とする電力変換器。 - 請求項3に記載の電力変換器において、
前記プリント配線板の下面側に導体パターン部が形成されてなり、
前記冷却用ヒートシンクの上面における前記放熱用絶縁層は、前記金属ブロックの下面に当接する領域と前記スルーホール部のランド面に当接する領域と前記導体パターン部のパターン面に当接する領域とを含むように形成されていることを特徴とする電力変換器。 - 請求項1または2に記載の電力変換器において、
前記中継電極は、金属材料として銅粒子を溶射して形成したことを特徴とする電力変換器。 - 請求項1または2に記載の電力変換器において、
前記放熱用絶縁層および/または前記中継電極用絶縁層は、熱伝導率が1〜200W/m・Kであり、かつ厚さが10〜500μmであることを特徴とする電力変換器。 - 請求項1または2に記載の電力変換器において、
前記放熱用絶縁層および/または前記中継電極用絶縁層は、酸化珪素、酸化アルミニウム、窒化珪素、窒化アルミニウム、窒化ホウ素からなるフィラー群の少なくとも1種類からなることを特徴とする電力変換器。 - 請求項7に記載の電力変換器において、
前記放熱用絶縁層および/または前記中継電極用絶縁層は、前記フィラー群の少なくとも1種によるセラミックス微粒子をプラズマ溶射法にて堆積させることにより形成したことを特徴とする電力変換器。 - 請求項7に記載の電力変換器において、
前記放熱用絶縁層および/または前記中継電極用絶縁層は、前記フィラー群の少なくとも1種によるセラミックス微粒子をエアロゾルデポジション法にて堆積させることにより形成したことを特徴とする電力変換器。
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