JP5989057B2 - Power converter - Google Patents

Description

  The present invention relates to a power conversion device including an inverter circuit.

  For example, a cooling structure shown in Patent Document 1 has been proposed as a conventional technique intended to efficiently transfer heat from a semiconductor module to a cooler to enhance heat dissipation. According to Patent Document 1, a semiconductor module is inserted into a module insertion hole formed in a cooler, and heat is radiated from a contact surface with the module insertion hole. It is disclosed that a soft metal layer is coated on the contact surface, and heat is radiated to the cooler through the soft metal layer.

  In addition, as a conventional technique intended to achieve both cooling efficiency and assemblability of a semiconductor element used in an inverter, for example, an inverter device shown in Patent Document 2 has been proposed. According to Patent Document 2, a housing portion that houses a power card in which both sides of a semiconductor element are sandwiched between heat sinks and a circulation path portion that circulates a cooling medium around the power card are formed. It is disclosed that the gap is filled with an insulating resin and the power card is fixed by curing the insulating resin.

  Moreover, the prior art of the cooling structure which aimed at the improvement of the cooling capability which reduced the burden of the assembly operation of a semiconductor module is proposed by patent document 3, for example. According to this Patent Document 3, a semiconductor module is accommodated therein, a block having heat radiation surfaces for radiating semiconductor generated heat is provided on the front surface and the back surface, and the block is inserted into a cooling water passage formed inside the case. Discloses that the front and back of the block face the cooling water passage.

JP 2005-175163 A JP 2005-237141 A JP 2006-202899 A

  2. Description of the Related Art In recent years, for example, in automobiles, the in-vehicle systems of vehicles, including vehicle drive systems, are being electrified. However, in the in-vehicle system electrification, a new addition of an electric machine that drives a driven body and a power conversion device that controls driving of the rotating electrical machine by controlling power supplied from the in-vehicle power source to the rotating electrical machine or the conventional It is necessary to replace the system components.

  For example, in an automobile, the power conversion device converts DC power supplied from a vehicle-mounted power source into AC power for driving the rotating electrical machine, or DC power for supplying AC power generated by the rotating electrical machine to the vehicle-mounted power source. It has a function to convert to electric power. Although the amount of power converted by the power conversion device tends to increase, since the whole automobile is in the direction of miniaturization and weight reduction, the increase in size and weight of the power conversion device is suppressed. In-vehicle power converters are required to be used in an environment with a large temperature change compared to industrial use, etc., and are comparatively small and comparatively capable of maintaining high reliability while placed in a high temperature environment. There is a demand for a power conversion device that can convert a large amount of power.

  The power conversion device includes an inverter circuit, and power conversion between DC power and AC power is performed by the operation of the inverter circuit. In order to perform this power conversion, it is necessary for the power semiconductor constituting the inverter circuit to repeat the switching operation (switching operation) between the cutoff state and the conduction state. During this switching operation, a large amount of heat is generated in the power semiconductor. The temperature of the semiconductor chip rises due to the heat generated during the switching operation of the semiconductor chip that is the power semiconductor of the inverter circuit. For this reason, it is an important subject to suppress this temperature rise.

  When the power to be converted increases, the amount of heat generated by the semiconductor chip increases, and as a countermeasure against this, it is necessary to increase the size of the semiconductor chip and the number of semiconductor chips used, resulting in an increase in the size of the power conversion device. As a method for suppressing such an increase in the size of the power converter, it is conceivable to improve the cooling efficiency of the semiconductor chip. For example, Patent Documents 1 to 3 are proposals made due to improvement in cooling efficiency of a semiconductor chip.

  Although it is clear that an improvement in the cooling efficiency of the semiconductor chip leads to a reduction in the size of the semiconductor chip, it is not always possible to suppress an increase in the size of the entire power conversion device. For example, if an improvement is made to improve the cooling efficiency of the semiconductor chip, the structure of the entire power conversion device may be complicated as a result, and the semiconductor chip can be reduced in size, but the entire power conversion device is viewed. It can happen that it cannot be downsized too much.

  Therefore, in order to suppress the increase in the size of the entire power conversion device, it is necessary to improve the cooling efficiency of the semiconductor chip in consideration of the entire power conversion device, and the electrical or mechanical complication of the entire power conversion device can be suppressed as much as possible. is necessary. In the known inventions described in Patent Documents 1 to 3, it cannot be said that sufficient consideration is given to downsizing of the entire power conversion device.

  The objective of this invention is providing the technique which leads to size reduction of a power converter device. Furthermore, the power conversion device according to the embodiment of the present invention described below includes not only miniaturization technology but also improvements related to improvement in reliability and improvement in productivity necessary for commercialization.

  One of the fundamental features in the present invention for solving the above problems is that a series circuit including an upper arm and a lower arm of an inverter circuit is built in one semiconductor module, and this semiconductor module is cooled on both sides. The semiconductor module for the upper arm and the semiconductor chip for the lower arm for constituting a series circuit having a metal and having an upper arm and a lower arm between the cooling metals is sandwiched, and the semiconductor module is inserted into the cooling water channel To do.

  The power conversion device according to the embodiment of the present invention described below solves many problems necessary for commercialization as described above. These problems and means for solving the problems will be described in detail below. Examples of the means for solving the problems mainly include the following configuration examples.

A plurality of semiconductor modules including a series circuit of upper and lower arms of an inverter circuit and having a DC positive terminal, a DC negative terminal, and an AC terminal;
A water channel forming body that forms a water channel between adjacent semiconductor modules among the plurality of semiconductor modules;
A capacitor module with a built-in capacitor ;
A bus bar assembly having an AC bus connected to the AC terminal ,
The plurality of semiconductor modules are fixed to the water channel forming body in a positional relationship arranged in parallel,
The capacitor module is disposed such that the side in the longitudinal direction of the capacitor module is parallel to the arrangement direction of the plurality of semiconductor modules,
Each of the plurality of semiconductor modules is arranged such that the DC positive terminal and the DC negative terminal are closer to the capacitor module than the AC terminal,
The capacitor module has a plurality of capacitor terminals arranged along the longitudinal side of the capacitor module;
Wherein the said DC positive terminal and the DC negative terminal of the plurality of semiconductor modules are the connection plurality of respective electrically to the capacitor terminals of the capacitor module,
The bus bar assembly is a power conversion device arranged at a position facing the capacitor module with the DC positive terminal and the DC negative terminal interposed therebetween .

In the above power converter, the capacitor module includes a capacitor-side positive terminal connected to the DC positive terminal, a capacitor-side negative terminal connected to the DC negative terminal, the capacitor-side positive terminal, and the capacitor. And an insulating member disposed between the side negative terminal and the power conversion device.

In the above power converter, the DC positive terminal, the DC negative terminal, the capacitor-side positive terminal, and the capacitor-side negative terminal are configured by a side surface and a main surface having a larger area than the side surface, The capacitor-side positive terminal extends to a position where the main surface of the capacitor-side positive terminal faces the main surface of the DC positive terminal, and is directly connected to the DC positive terminal. The power converter device by which the main surface of a side negative electrode terminal is extended to the position facing the main surface of the said DC negative electrode terminal, and is directly connected with the said DC negative electrode terminal.

Moreover, in the above-described power conversion device, the capacitor module is a power conversion device fixed to the water channel forming body .

The power converter described above further includes a bus bar assembly having an AC bus connected to the AC terminal, and the bus bar assembly is disposed at a position facing the capacitor module with the positive electrode terminal and the negative electrode terminal interposed therebetween. that the power conversion device.

  ADVANTAGE OF THE INVENTION According to this invention, the cooling efficiency of the semiconductor chip which comprises an inverter circuit can be improved. This improvement in cooling performance not only reduces the size of the semiconductor module, but also leads to downsizing of the entire inverter device.

  The power conversion device according to the embodiment of the present invention solves many problems necessary for commercialization in addition to downsizing which is the effect of the above-described invention, and has an effect. Then, the solutions to the many problems and the effects obtained by solving them will be described in detail in conjunction with the description of the present embodiment in the section of the embodiment for carrying out the invention described below.

It is a figure which shows the control block of a hybrid vehicle. FIG. 2 is a diagram showing a circuit configuration of an electric vehicle driving electric machine system including an inverter device including an upper and lower arm series circuit and a control unit, a power conversion device including a capacitor connected to the DC side of the inverter device, a battery, and a motor generator. is there. It is a figure which shows the circuit structure of the power converter device which uses two upper-lower arm series circuits for each phase alternating current output to a motor generator. It is a figure which shows the external appearance shape of the power converter device which concerns on embodiment of this invention. It is an exploded view which perspectively shows the internal structure of the power converter device concerning this embodiment. It is the perspective view which removed the upper case from the power converter device which concerns on this embodiment. It is the perspective view which removed the upper case, the capacitor | condenser, and the bus-bar assembly from the power converter device which concerns on this embodiment. It is a structural example of 2 inverter apparatuses in the power converter device which concerns on this embodiment, and is the perspective view which removed the bus-bar assembly and the upper case. It is a structural example of 2 inverter apparatuses in the power converter device which concerns on this embodiment, and is the perspective view which removed the bus-bar assembly, the upper case, and the capacitor | condenser module. It is a structural example of 2 inverter apparatuses in the power converter device which concerns on this embodiment, and is a top view which removed the bus-bar assembly, the upper case, and the capacitor | condenser module. It is sectional drawing which shows the cooling water flow of the water channel housing | casing loaded with the semiconductor module regarding this embodiment. It is sectional drawing which shows the cooling water flow of the water channel housing | casing in which the semiconductor module in the 2 inverter apparatus shown in FIG. 9 was loaded. It is a top view which shows the arrangement | positioning condition in the water channel housing | casing of the positive electrode terminal of a semiconductor module connected in parallel with respect to each phase to the motor shown in FIG. 3, a negative electrode terminal, an alternating current terminal, a signal terminal, and a gate terminal. It is the perspective view which expand | deployed the canal case main body part which loaded the semiconductor module, the canal case front part, and the canal case back part. It is sectional drawing which expand | deployed the canal body main part which loaded the semiconductor module, the canal case front part, and the canal case back part. It is a perspective view which shows the condition which loads a semiconductor module in a water channel housing | casing main-body part. It is a front view which shows the condition which loads a semiconductor module in a road housing main-body part. It is a figure which shows the external appearance of the semiconductor module with a radiation fin which incorporates the upper-and-lower arm series circuit in the power converter device which concerns on this embodiment. It is sectional drawing of the semiconductor module shown in FIG. It is an expanded view of the semiconductor module including a case. It is sectional drawing of the semiconductor module shown in FIG. It is a figure which expands the radiation fin (A side) of the one side of the semiconductor module regarding this embodiment, and expands the radiation fin (B side) of the other side, and shows an internal structure perspectively. It is a figure which shows the structure of the upper-lower arm series circuit fixed to the inner side of the radiation fin (A side) of a semiconductor module. It is a perspective view which shows the structure of the upper-and-lower arm series circuit fixed to the inner side of the radiation fin (B side) of a semiconductor module. It is a perspective view which shows the structure of the upper-lower arm series circuit fixed to the inner side of the radiation fin (A side) of a semiconductor module. FIG. 26 is a front view of FIG. 25. It is a perspective view which shows the structure and wire bonding state of a conductor plate which are vacuum-thermocompression bonded inside the radiation fin of a semiconductor module. It is explanatory drawing which carries out the vacuum thermocompression bonding of the conductor board to the radiation fin of a semiconductor module via a thermal radiation sheet. It is a figure showing the cooling water flow of the radiation fin (A side) in the semiconductor module regarding this embodiment. It is a figure showing the relationship between the cooling water flow in a semiconductor module, and arrangement | positioning of a circuit structure. It is a figure which shows the connection terminal of the capacitor | condenser module of the power converter device which concerns on this embodiment. It is a perspective view which shows the connection state of the semiconductor module and capacitor | condenser module regarding this embodiment. It is sectional drawing which shows the connection state of the semiconductor module and capacitor | condenser module regarding this embodiment. It is a structural layout for explaining the inductance reduction effect of the semiconductor module according to this embodiment. It is a layout on a circuit explaining the inductance reduction effect of the semiconductor module concerning this embodiment. It is a perspective view which shows the other structural example of the semiconductor module regarding this embodiment. It is sectional drawing which shows the other structural example of the semiconductor module regarding this embodiment, and is the figure seen from the dotted-line arrow of FIG. It is a perspective view explaining the flow of the cooling water in the other structural example of the semiconductor module regarding this embodiment. It is sectional drawing which shows the flow of the cooling water at the time of mounting the other structural example of the semiconductor module regarding this embodiment in the water cooling housing | casing. It is other sectional drawing which shows the flow of the cooling water of two steps of upper and lower when the other structural example of the semiconductor module regarding this embodiment is loaded in the water cooling housing | casing. It is a figure which shows the structural example which expands the area of the emitter electrode of the IGBT chip | tip in a semiconductor module. It is a figure which shows the structure by which the control board which has a control circuit shown in FIG. 5 is arrange | positioned at the bottom part of a water channel housing | casing.

  A power conversion device according to an embodiment of the present invention will be described in detail below with reference to the drawings. First, a technical problem to be improved and improved in the power conversion device according to the present embodiment and this technical problem are first described. An outline of a technique for solving the problem will be described.

  The power conversion device according to the embodiment of the present invention considers the following technical viewpoint as a product that meets the needs of the world, and one of the viewpoints is miniaturization technology, that is, accompanying an increase in power to be converted. This is a technology that suppresses the enlargement of the power converter as much as possible. Furthermore, another viewpoint is a technique related to improvement of the reliability of the power conversion apparatus, and still another viewpoint is a technique related to improvement of productivity of the power conversion apparatus. And the power converter device which concerns on embodiment of this invention is commercialized based on the viewpoint which combined the above-mentioned three viewpoints, and also these viewpoints, The characteristic of the power converter device in each viewpoint is shown. Listed below and outlined.

(1) Description of Miniaturization Technology In the power conversion device according to this embodiment, a series circuit of upper and lower arms of an inverter is housed in a semiconductor module having cooling metals on both sides, and the semiconductor module is inserted into cooling water. The cooling metal on both sides is cooled with cooling water. With this structure, the cooling efficiency is improved, and the semiconductor module can be miniaturized. Further, as a specific structure, an insulating member such as an insulating sheet or a ceramic plate is provided inside the cooling metal on both sides, and a series circuit of upper and lower arms is provided between the conductor metals fixed to each insulating member. The upper and lower arm semiconductor chips are sandwiched. With this structure, good heat conduction paths can be formed between both surfaces of the upper and lower semiconductor chips and the cooling metal, and the cooling efficiency of the semiconductor module is greatly improved.

  Moreover, in the semiconductor module, the semiconductor chips of the upper arm and the lower arm are shifted in the direction perpendicular to the cooling water flow axis, so that the cooling water in the cooling water channel can be used more efficiently and cooling. The effect is improved.

  Further, the semiconductor chip of the upper arm of the semiconductor module and the semiconductor chip of the lower arm of the semiconductor module are arranged so as to be shifted in the direction perpendicular to the flow axis of the cooling water, and at a position corresponding to the semiconductor chip of the upper arm. By dividing the water channel and the water channel at the position corresponding to the semiconductor chip of the lower arm and connecting these water channels in series, the cross-sectional area of the water channel can be narrowed to match the semiconductor chip to be cooled, As a result, the flow rate of the cooling water in the water channel can be increased. Increasing this flow rate increases the amount of water that contributes to cooling per unit time, leading to a significant improvement in cooling efficiency. The structure in which the water channel is divided into the position corresponding to the semiconductor chip of the upper arm or the lower arm does not complicate the cooling structure as a whole, and the cooling efficiency does not increase so much. There is an effect that can be greatly improved.

  Both surfaces of the semiconductor chip of the upper arm and the lower arm are respectively connected to a conductor metal (conductor plate) inside the cooling metal, and the conductor metal is fixed to the cooling metal via an insulating member. The thickness of the insulating member is thin, for example, 350 μm or less in the case of a ceramic plate, and is further thinner from 50 μm to 200 μm in the case of an insulating sheet. Here, the insulating sheet is, for example, a thermocompression-bonded resin sheet. Since the conductor metal is provided close to the cooling metal, the eddy current due to the current flowing through the conductor metal flows through the cooling metal, and the eddy current generates heat, but these heat is efficiently transferred to the cooling water.

  Further, the inductance in the semiconductor module is reduced by the eddy current. The inductance reduction can reduce the jump of voltage due to the switching operation of the semiconductor chips of the upper arm and the lower arm, leading to an improvement in reliability. In addition, the suppression of the voltage rise enables the switching operation of the semiconductor chip of the upper arm and the lower arm to be speeded up, the time for the switching operation can be shortened, and the amount of heat generated by the switching operation is reduced.

  In the power conversion device according to the present embodiment, since the series circuit of the upper and lower arms of the inverter is housed inside the semiconductor module, the structure in which the DC terminal of the semiconductor module is connected to the capacitor module, and further the terminal structure of the capacitor module is This makes the structure very simple, which greatly contributes to the miniaturization of the entire inverter device, and at the same time leads to improved reliability and productivity.

  Also, the DC terminal of the semiconductor module, the terminal structure of the capacitor module, and the structure for connecting them are arranged so that the terminals on the positive electrode side and the negative electrode side and the conductors connected to these terminals are close to each other and facing each other. Thus, the inductance between the semiconductor module and the capacitor can be reduced. As a result, voltage jump due to the switching operation of the semiconductor chips of the upper and lower arms can be reduced, leading to improvement in reliability. In addition, the suppression of the voltage rise enables the switching operation of the semiconductor chip to be speeded up, leading to a reduction in the amount of heat generated by shortening the switching operation time. By reducing the amount of heat generation or the complexity of the connection structure, the power converter can be downsized.

  Further, in the power conversion device according to the present embodiment, the cooling efficiency is greatly improved, so that the engine cooling water can be used as the cooling water. When cooling with cooling water different from engine cooling water, the automobile needs a new cooling system, and even if the power converter can be reduced in size, the entire automobile becomes complicated. In the present embodiment, even if the power conversion device is enlarged, engine cooling water can be used, so that the entire vehicle is downsized and has many advantages.

  Since the power conversion device according to the present embodiment is configured to fix the semiconductor module or the capacitor module to the cooling housing, the surface of the cooling housing provided with the semiconductor module can be used as a surface for fixing the capacitor module. Can be reduced in size. Furthermore, the cooling efficiency of the capacitor module is improved, and the capacitor module can be firmly held by the cooling housing, so that it is resistant to vibrations, and has the effect of miniaturization and improved reliability.

(2) Description of Reliability Improvement In the power conversion device according to this embodiment, as described above, the cooling efficiency of the semiconductor module can be greatly improved, and as a result, the temperature rise of the semiconductor chip can be suppressed, and the reliability is improved. It leads to improvement.

  Further, it is possible to reduce the inductance of the semiconductor module and the inductance between the semiconductor module and the capacitor module, and it is possible to reduce the jump of the voltage due to the switching operation, leading to the improvement of the reliability. In addition, the suppression of the voltage rise makes it possible to increase the switching speed of the semiconductor chip, leading to a reduction in the amount of heat generated by shortening the switching operation time, which in turn suppresses the temperature rise and leads to an improvement in reliability.

  The structure in which the DC terminal of the semiconductor module is connected to the capacitor module, and further the terminal structure of the capacitor module is simplified, leading to not only improvement in productivity and size reduction but also improvement in reliability.

  In this power converter, since the cooling efficiency is greatly improved, the engine cooling water can be used as the cooling water. For this reason, a dedicated cooling water system is unnecessary for the automobile, and the reliability of the entire automobile is greatly improved.

  In this power converter, the structure which inserts and fixes the semiconductor module which accommodated the series circuit of the upper and lower arm of an inverter in a water channel from the opening provided in the cooling water channel is comprised. It is possible to inspect the semiconductor module and the water channel casing separately manufactured on the manufacturing line, respectively, and then perform a process of fixing the semiconductor module to the water channel casing. In this way, it is possible to separately manufacture and inspect the semiconductor module that is an electrical component and the water channel casing that is a mechanical component, which leads to improvement in reliability as well as improvement in productivity.

  Further, in the semiconductor module, a method of manufacturing a semiconductor module by fixing necessary conductors and semiconductor chips to the first and second heat radiating metals, respectively, and then integrating the first and second heat radiating metals. Is possible. It becomes possible to perform the process of integrating the heat dissipation metal after confirming the manufacturing states of the first and second heat dissipation metals, leading to not only improvement of productivity but also improvement of reliability. Furthermore, the DC terminal, AC terminal, signal terminal (signal emitter terminal), and gate terminal of the semiconductor module are fixed to either the first or second heat dissipation metal inside the semiconductor module. Enhances vibration and reliability.

  In this power converter, when the collector surface of the semiconductor chip of the upper arm is fixed to the first heat radiating metal, the collector surface of the semiconductor chip of the lower arm is similarly fixed to the first heat radiating metal. The collector surface and the emitter surface of the semiconductor chip are in the same direction. With such a structure, productivity is improved and reliability is improved.

  Further, the semiconductor chip of the upper and lower arms and the signal terminals and gate terminals of the upper and lower arms are fixed to the same heat radiating metal. For this reason, the wire bonding connection process for connecting the semiconductor chip to the signal terminal and the gate terminal can be concentrated on one heat dissipating metal, which facilitates inspection and the like. This not only improves productivity but also improves reliability.

(3) Description Regarding Productivity Improvement In the power conversion device according to the present embodiment, as described above, the semiconductor module and the cooling housing are separately manufactured, and then the semiconductor module is fixed to the cooling housing. It is possible to manufacture a semiconductor module on an electric production line. This improves productivity and reliability. Similarly, the capacitor module can be manufactured in another manufacturing process and then fixed to the water channel casing, so that productivity is improved.

  In addition, the semiconductor module and the capacitor module can be fixed to the water channel housing, and then the terminal connection between the semiconductor module and the capacitor module can be performed. It leads to improvement of productivity. In these connection processes, the terminals of the semiconductor module are fixed to the heat dissipating metal of the semiconductor module, respectively, and the heat at the time of terminal welding diffuses to the heat dissipating metal, respectively, which can suppress adverse effects on the semiconductor chip. This leads to improved productivity and reliability.

  In addition, since the semiconductor chip of the upper and lower arms and the signal terminals and gate terminals of the upper and lower arms can be fixed to one heat radiating metal of the semiconductor module, wire bonding of both the upper arm and the lower arm is performed on one heat radiating metal production line. Can improve productivity.

  The power conversion device according to the present embodiment mass-produces semiconductor modules having the same structure, and can adopt a method of using a required number of semiconductor modules based on the required specifications of the power conversion device. As a result, productivity can be improved and price reduction and reliability can be improved. This is the end of the description of the structural features and effects of the power conversion device according to the embodiment of the present invention from the three technical viewpoints.

  Next, a power converter according to an embodiment of the present invention will be described in detail with reference to the drawings. The power conversion device according to the embodiment of the present invention can be applied to a hybrid vehicle or a pure electric vehicle. As a representative example, a control configuration when the power conversion device according to the embodiment of the present invention is applied to a hybrid vehicle. The circuit configuration of the power converter will be described with reference to FIGS. FIG. 1 is a diagram showing a control block of a hybrid vehicle. FIG. 2 shows an inverter device including a series circuit of upper and lower arms and a control unit, a power conversion device including a capacitor connected to the direct current side of the inverter device, a battery, and a motor drive circuit having a motor generator. It is a figure which shows a structure.

  The power conversion device according to the embodiment of the present invention is used in a vehicle-mounted power conversion device for a vehicle-mounted electrical system mounted on an automobile, in particular, a vehicle drive electrical system, and has a very severe mounting environment and operational environment. The inverter device will be described as an example. A vehicle drive inverter device is provided in a vehicle drive electrical system as a control device for controlling the drive of a vehicle drive motor, and a DC power supplied from an onboard battery or an onboard power generator constituting an onboard power source is a predetermined AC power. Then, the AC power obtained is supplied to the vehicle drive motor to control the drive of the vehicle drive motor. Further, since the vehicle drive motor also has a function as a generator, the vehicle drive inverter device also has a function of converting the AC power generated by the vehicle drive motor into DC power according to the operation mode. Yes. The converted DC power is supplied to the vehicle battery.

  The configuration of the present embodiment can be applied to an inverter device other than the vehicle driving device, for example, an inverter device used as a control device of an electric brake device or an electric power steering device, but it is most desirable when applied to a vehicle driving device. Demonstrate the effect. The idea of this embodiment can also be applied to other in-vehicle power converters such as DC / DC converters and DC / DC power converters such as DC / DC converters or AC / DC power converters. To achieve the most dramatic effect. Furthermore, an industrial power conversion device used as a control device for an electric motor that drives factory equipment, or a home power conversion device used for a control device for an electric motor that drives a household solar power generation system or household electrical appliance However, as described above, the most desirable effect can be achieved by applying it for vehicle driving.

  In addition, the vehicle drive electric machine system including the vehicle drive inverter device to which the present embodiment is applied uses an engine that is an internal combustion engine and a vehicle drive motor as a vehicle drive source, and drives one of the front and rear wheels. The case where it mounts in the hybrid vehicle comprised in this way is mentioned as an example, and is demonstrated. Further, some hybrid vehicles drive one of the front and rear wheels by an engine and the other one of the front and rear wheels by a vehicle driving motor. However, this embodiment can be applied to any hybrid vehicle. Furthermore, as described above, the present invention can also be applied to a pure electric vehicle such as a fuel cell vehicle. In a pure electric vehicle, the power conversion device described below performs substantially the same operation, and substantially the same effect can be obtained.

  In FIG. 1, a hybrid electric vehicle (hereinafter referred to as “HEV”) 10 is one electric vehicle, and includes two vehicle drive systems. One of them is an engine system that uses an engine 20 that is an internal combustion engine as a power source. The engine system is mainly used as a drive source for HEV. The other is an in-vehicle electric system using motor generators 92 and 94 as a power source. The in-vehicle electric system is mainly used as an HEV drive source and an HEV power generation source. The motor generators 92 and 94 are, for example, permanent magnet synchronous motors. However, the motor generators 92 and 94 operate as both motors and generators depending on the operation method.

  A front wheel axle 14 is rotatably supported at the front portion of the vehicle body. A pair of front wheels 12 are provided at both ends of the front wheel axle 14. A rear wheel axle (not shown) is rotatably supported on the rear portion of the vehicle body. A pair of rear wheels are provided at both ends of the rear wheel axle. The HEV of the present embodiment employs a so-called front wheel drive system in which the main wheel driven by power is the front wheel 12 and the driven wheel to be driven is the rear wheel. You may adopt.

  A front wheel side differential gear (hereinafter referred to as “front wheel side DEF”) 16 is provided at the center of the front wheel axle 14. The front wheel axle 14 is mechanically connected to the output side of the front wheel side DEF 16. The output shaft of the transmission 18 is mechanically connected to the input side of the front wheel side DEF16. The front wheel side DEF 16 is a differential power distribution mechanism that distributes the rotational driving force that is shifted and transmitted by the transmission 18 to the left and right front wheel axles 14. The output side of the motor generator 92 is mechanically connected to the input side of the transmission 18. The output side of the engine 20 and the output side of the motor generator 94 are mechanically connected to the input side of the motor generator 92 via the power distribution mechanism 22. The motor generators 92 and 94 and the power distribution mechanism 22 are housed inside the casing of the transmission 18.

  The power distribution mechanism 22 is a differential mechanism composed of gears 23 to 30. The gears 25 to 28 are bevel gears. The gears 23, 24, 29, and 30 are spur gears. The power of the motor generator 92 is directly transmitted to the transmission 18. The shaft of the motor generator 92 is coaxial with the gear 29. With this configuration, when drive power is not supplied to the motor generator 92, the power transmitted to the gear 29 is transmitted to the input side of the transmission 18 as it is.

  When the gear 23 is driven by the operation of the engine 20, the power of the engine 20 is transferred from the gear 23 to the gear 24, then from the gear 24 to the gear 26 and the gear 28, and then from the gear 26 and the gear 28 to the gear 30. Each is transmitted, and finally transmitted to the gear 29. When the gear 25 is driven by the operation of the motor generator 94, the rotation of the motor generator 94 is transmitted from the gear 25 to the gear 26 and the gear 28, and then from the gear 26 and the gear 28 to the gear 30 respectively. It is transmitted to the gear 29. As the power distribution mechanism 22, other mechanisms such as a planetary gear mechanism may be used instead of the above-described differential mechanism.

  The motor generators 92 and 94 are synchronous machines having permanent magnets on the rotor, and the AC generators 92 and 94 are controlled by the inverter devices 40 and 42 by controlling the AC power supplied to the armature windings of the stator. Is controlled. A battery 36 is electrically connected to the inverter devices 40 and 42, and power can be exchanged between the battery 36 and the inverter devices 40 and 42.

  In the present embodiment, the first motor generator unit composed of the motor generator 92 and the inverter device 40 and the second motor generator unit composed of the motor generator 94 and the inverter device 42 are provided, and they are selectively used according to the operating state. ing. That is, in the case where the vehicle is driven by the power from the engine 20, when assisting the driving torque of the vehicle, the second motor generator unit is operated by the power of the engine 20 as a power generation unit to generate power, and the power generation The first electric power generation unit is operated as an electric unit by the obtained electric power. Further, in the same case, when assisting the vehicle speed of the vehicle, the first motor generator unit is operated by the power of the engine 20 as a power generation unit to generate power, and the second motor generator unit is generated by the electric power obtained by the power generation. Operate as an electric unit.

  In the present embodiment, the vehicle can be driven only by the power of the motor generator 92 by operating the first motor generator unit as an electric unit by the electric power of the battery 36. Further, in the present embodiment, the battery 36 can be charged by operating the first motor generator unit or the second motor generator unit as a power generation unit by using the power of the engine 20 or the power from the wheels to generate power.

  Next, the electric circuit configuration of the inverter devices 40 and 42 will be described with reference to FIG. In the embodiment shown in FIGS. 1 to 2, the case where the inverter devices 40 and 42 are individually configured will be described as an example. However, as will be described later with reference to FIG. May be stored in one apparatus. Since the inverter devices 40 and 42 have the same configuration and perform the same functions and have the same functions, the inverter device 40 will be described here as an example.

  The power conversion device 100 according to the present embodiment includes an inverter device 40 and a capacitor 90, and the inverter device 40 includes an inverter circuit 44 and a control unit 70. Further, the inverter circuit 44 includes a plurality of upper and lower arm series circuits 50 each including an IGBT 52 (insulated gate bipolar transistor) and a diode 56 that operate as an upper arm, and an IGBT 62 and a diode 66 that operate as a lower arm (FIG. 2). In this example, three upper and lower arm series circuits 50, 50, 50) and an AC power line 86 to the motor generator 92 are drawn from the middle point (intermediate electrode 69) of each upper and lower arm series circuit 50 through an AC terminal 59. . Further, the control unit 70 includes a driver circuit 74 that drives and controls the inverter circuit 44 and a control circuit 72 (built in the control board) that supplies a control signal to the driver circuit 74 via a signal line 76.

  The IGBTs 52 and 62 of the upper arm and the lower arm are switching power semiconductor elements, operate in response to a drive signal output from the control unit 70, and convert DC power supplied from the battery 36 into three-phase AC power. . The converted electric power is supplied to the armature winding of the motor generator 92. As described above, the three-phase AC power generated by the motor generator 92 can be converted into DC power.

  The power conversion apparatus 100 according to the present embodiment is configured by a three-phase bridge circuit, and upper and lower arm series circuits 50, 50, 50 for three phases are electrically connected between the positive electrode side and the negative electrode side of the battery 36, respectively. It is configured by being connected in parallel. Here, the upper and lower arm series circuit 50 is called an arm, and includes an upper arm side switching power semiconductor element 52 and a diode 56, and a lower arm side switching power semiconductor element 62 and a diode 66.

  In the present embodiment, the use of IGBTs (insulated gate bipolar transistors) 52 and 62 as power semiconductor elements for switching is exemplified. The IGBTs 52 and 62 include collector electrodes 53 and 63, emitter electrodes, gate electrodes (gate electrode terminals 54 and 64), and signal emitter electrodes (signal emitter electrode terminals 55 and 65). Diodes 56 and 66 are electrically connected between the collector electrodes 53 and 63 and the emitter electrodes of the IGBTs 52 and 62 as shown in the figure. The diodes 56 and 66 have two electrodes, a cathode electrode and an anode electrode. The cathode electrode serves as the collector electrode of the IGBTs 52 and 62 so that the direction from the emitter electrode to the collector electrode of the IGBTs 52 and 62 is the forward direction. The anode electrode is electrically connected to the emitter electrodes of the IGBTs 52 and 62, respectively.

  A MOSFET (metal oxide semiconductor field effect transistor) may be used as the power semiconductor element for switching. The MOSFET includes three electrodes, a drain electrode, a source electrode, and a gate electrode. Note that the MOSFET includes a parasitic diode between the source electrode and the drain electrode whose forward direction is from the drain electrode to the source electrode. For this reason, unlike the IGBT, there is no need to provide a separate diode.

  The upper and lower arm series circuit 50 is provided for three phases corresponding to each phase winding of the armature winding of the motor generator 92. The three upper and lower arm series circuits 50, 50, 50 respectively provide an U electrode, a V phase, and a W phase to the motor generator 92 via an intermediate electrode 69 that connects the emitter electrode of the IGBT 52 and the collector electrode 63 of the IGBT 62, and an AC terminal 59. Forming. The upper and lower arm series circuits are electrically connected in parallel. The collector electrode 53 of the upper arm IGBT 52 is connected to the positive electrode capacitor electrode of the capacitor 90 via the positive electrode terminal (P terminal) 57, and the emitter electrode of the lower arm IGBT 62 is connected to the negative electrode of the capacitor 90 via the negative electrode terminal (N terminal) 58. Each of the side capacitor electrodes is electrically connected. An intermediate electrode 69 corresponding to the middle point portion of each arm (the connection portion between the emitter electrode of the IGBT 52 of the upper arm and the collector electrode of the IGBT 62 of the lower arm) is connected to the corresponding phase winding of the armature winding of the motor generator 92 with an AC connector. 88 is electrically connected. In the present embodiment, as will be described in detail later, one upper and lower arm series circuit 50 including upper and lower arms is a main circuit component of the semiconductor module.

  Capacitor 90 is for constituting a smoothing circuit that suppresses fluctuations in the DC voltage caused by the switching operation of IGBTs 52 and 62. A positive electrode side of the battery 36 is electrically connected to the positive electrode side capacitor electrode of the capacitor 90, and a negative electrode side of the battery 36 is electrically connected to the negative electrode side capacitor electrode of the capacitor 90 via the DC connector 38. Thereby, the capacitor 90 is connected between the collector electrode 53 of the upper arm IGBT 52 and the positive electrode side of the battery 36, and between the emitter electrode of the lower arm IGBT 62 and the negative electrode side of the battery 36, and is connected in series with the battery 36. Electrically connected to the circuit 50 in parallel.

  The control unit 70 is for operating the IGBTs 52 and 62, and generates a timing signal for controlling the switching timing of the IGBTs 52 and 62 based on input information from other control devices and sensors. (Built in the control board) and a drive circuit 74 for generating a drive signal for switching the IGBTs 52 and 62 based on the timing signal output from the control circuit 72.

  The control circuit 72 includes a microcomputer (hereinafter referred to as “microcomputer”) for calculating the switching timing of the IGBTs 52 and 62. The microcomputer receives as input information the target torque value required for the motor generator 92, the current value supplied from the upper and lower arm series circuit 50 to the armature winding of the motor generator 92, and the magnetic pole of the rotor of the motor generator 92. The position has been entered. The target torque value is based on a command signal output from a host controller (not shown). The current value is detected based on the detection signal output from the current sensor 80. The magnetic pole position is detected based on a detection signal output from a rotating magnetic pole sensor (not shown) provided in the motor generator 92. In the present embodiment, the case where the current values of three phases are detected will be described as an example, but the current values for two phases may be detected.

  The microcomputer in the control circuit 72 calculates the d and q axis current command values of the motor generator 92 based on the target torque value, and the calculated d and q axis current command values and the detected d and q The voltage command values for the d and q axes are calculated based on the difference from the current value of the shaft, and the calculated voltage command values for the d and q axes are calculated based on the detected magnetic pole position. Convert to W phase voltage command value. Then, the microcomputer generates a pulse-like modulated wave based on a comparison between the fundamental wave (sine wave) and the carrier wave (triangular wave) based on the voltage command values of the U phase, V phase, and W phase, and the generated modulation wave The wave is output to the driver circuit 74 as a PWM (pulse width modulation) signal. The driver circuit 74 outputs six PWM signals from the microcomputer corresponding to the upper and lower arms of each phase. Other signals such as a rectangular wave signal may be used as the timing signal output from the microcomputer.

  The driver circuit 74 is configured by an integrated circuit in which a plurality of electronic circuit components are integrated into one, a so-called driver IC. In the present embodiment, a case where one IC is provided for each of the upper and lower arms of each phase (1 arm in 1 module: 1 in 1) will be described as an example, but one arm corresponding to each arm. An IC may be provided (2 in 1), or one IC may be provided corresponding to all the arms (6 in 1). When driving the lower arm, the driver circuit 74 amplifies the PWM signal. When the driver circuit 74 drives the upper arm to the gate electrode of the corresponding IGBT 62 of the lower arm, the driver circuit 74 sets the level of the reference potential of the PWM signal. After shifting to the level of the reference potential of the upper arm, the PWM signal is amplified and output as a drive signal to the gate electrode of the corresponding IGBT 52 of the upper arm. Thereby, each IGBT52 and 62 performs switching operation based on the input drive signal.

  In addition, the control unit 70 performs abnormality detection (overcurrent, overvoltage, overtemperature, etc.) and protects the upper and lower arm series circuit 50. For this reason, sensing information is input to the control unit 70. For example, information on the current flowing through the emitter electrodes of the IGBTs 52 and 62 is input from the signal emitter electrode terminals 55 and 65 of each arm to the corresponding drive unit (IC). Thereby, each drive part (IC) detects overcurrent, and when overcurrent is detected, it stops the switching operation of corresponding IGBT52,62, and protects corresponding IGBT52,62 from overcurrent. Information on the temperature of the upper and lower arm series circuit 50 is input to the microcomputer from a temperature sensor (not shown) provided in the upper and lower arm series circuit 50. Further, information on the voltage on the DC positive side of the upper and lower arm series circuit 50 is input to the microcomputer. The microcomputer performs over-temperature detection and over-voltage detection based on such information, and when an over-temperature or over-voltage is detected, stops the switching operation of all the IGBTs 52 and 62, and the upper and lower arm series circuit 50 (by pulling) The semiconductor module including the circuit 50 is protected from overtemperature or overvoltage.

  In FIG. 2, an upper and lower arm series circuit 50 is a series circuit of an upper arm IGBT 52 and an upper arm diode 56, and a lower arm IGBT 62 and a lower arm diode 66. The IGBTs 52 and 62 are switching semiconductor elements. . The conduction and cut-off operations of the IGBTs 52 and 62 of the upper and lower arms of the inverter circuit 44 are switched in a certain order, and the current of the stator winding of the motor generator 92 at the time of switching flows through a circuit formed by the diodes 56 and 66.

  As shown in the figure, the upper and lower arm series circuit 50 includes a positive terminal (P terminal, positive terminal) 57, a negative terminal (N terminal 58, negative terminal), an AC terminal 59 from the intermediate electrode 69 of the upper and lower arms, and an upper arm signal. A signal terminal (signal emitter electrode terminal) 55, an upper arm gate electrode terminal 54, a lower arm signal terminal (signal emitter electrode terminal) 65, and a lower arm gate terminal electrode 64. The power conversion apparatus 100 has a DC connector 38 on the input side and an AC connector 88 on the output side, and is connected to the battery 36 and the motor generator 92 through the connectors 38 and 88.

  FIG. 3 is a diagram showing a circuit configuration of a power conversion device that uses two upper and lower arm series circuits for each phase as a circuit that generates an output of each phase of a three-phase AC output to the motor generator. As the capacity of the motor generator increases, the amount of power converted by the power converter increases, and the value of current flowing through the upper and lower arm DC circuits of each phase of the inverter circuit 44 increases. Increasing the electric capacity of the upper and lower arms can cope with an increase in the conversion power, but it is preferable to increase the production amount of the inverter module. In FIG. 3, the number of inverter modules produced by standardization is used. To increase the amount of power to be converted. FIG. 3 shows a circuit configuration in which the capacity of the inverter circuit 44 is increased in accordance with the capacity of the motor generator by connecting two upper and lower arm DC circuits of the inverter circuit 44 in parallel as an example.

  As a specific configuration of the power converter, upper and lower arm series circuits 50U1 and 50U2 are connected in parallel to the U phase, and the AC terminals 59-1 and 59-2 are connected to form a U-phase AC power line. As the U phase for the motor generator, the P terminal is provided with 57-1 (P1 terminal) and 57-2 (P2 terminal), and the N terminal is provided with 58-1 (N1 terminal) and 58-2 (N2 terminal). The AC terminals are provided with 59-1 and 59-2. Similarly, the V phase and the W phase are also connected in parallel.

  In this circuit configuration, the voltages between the P and N terminals of the upper and lower arm series circuits of each phase connected in parallel, for example, the upper and lower arm series circuits 50U1 and 50U2, are equal, and the upper and lower arm series circuits 50U1 and 50U2 It is desirable to always distribute current evenly. For this purpose, it is desirable to make the distributed inductance and other electrical conditions of the upper and lower arm series circuits 50U1 and 50U2 connected in parallel as equal as possible.

  In the power conversion device according to the present embodiment described below, a semiconductor module 50U1 having a built-in upper and lower arm series circuit 50U1 and a semiconductor module 50U2 having a built-in upper and lower arm series circuit 50U2 are disposed adjacent to each other, and each of these P terminals and Since the interval between the N terminal and the terminal of the capacitor module is made equal and the electrical conditions such as the connection method are matched (see FIG. 13), the upper and lower arm series circuit 50U1 constituting each phase, for example, the U phase is incorporated. Current flowing in the semiconductor module 50U1 and the semiconductor module 50U2 incorporating the upper and lower arm series circuit 50U2 are substantially equal, and the terminal voltages of the semiconductor modules 50U1 and 50U2 are substantially equal. Since the upper and lower arm series circuits connected in parallel constituting each phase of the inverter circuit 44 perform the switching operation at the same timing, the same signal is output from the control unit 70 for each phase of the U phase, the V phase, and the W phase. Are sent to each upper and lower arm series circuit constituting these phases.

  Further, when the vehicle has two motor generators as shown in FIG. 1, the vehicle has two sets of the power converters shown in FIG. 2 or FIG. 3. Whether it is the circuit of FIG. 2 or the circuit of FIG. 3 is determined by the specifications of the motor generator as described above. When the circuit shown in FIG. 2 is insufficient with respect to the electric power of the motor generator, the number of semiconductor modules standardized as shown in FIG. The power converters shown in FIG. 2 or FIG. 3 may be provided for two motor generators, respectively, but two inverter circuits are provided in one power converter, and two inverter circuits are provided in one water channel housing. By providing the semiconductor module that constitutes, it is much smaller than providing two power conversion devices. Moreover, it is superior to providing two power converters from the viewpoint of productivity and reliability. A power converter provided with such two inverter circuits will be described later with reference to FIG.

  Next, the manufacturing method and structure of the semiconductor module in the power conversion device according to the embodiment of the present invention will be described in detail below with reference to FIGS. FIG. 18 is a view showing the appearance of a semiconductor module with heat radiation fins that incorporates upper and lower arm series circuits in the power conversion apparatus according to the present embodiment. FIG. 19 is a cross-sectional view of the semiconductor module shown in FIG. FIG. 20 is a development view of the semiconductor module including the case. 21 is a cross-sectional view of the semiconductor module shown in FIG.

  FIG. 22 is a perspective view showing the internal structure of the semiconductor module according to the present embodiment by developing one side of the radiation fin (A side) and the other side of the radiation fin (B side). FIG. 23 is a view showing the structure of the upper and lower arm series circuit fixed inside the heat radiating fin (A side) of the semiconductor module. FIG. 24 is a perspective view showing the structure of the upper and lower arm series circuit fixed to the inside of the heat radiation fin (B side) of the semiconductor module. FIG. 25 is a perspective view showing the structure of the upper and lower arm series circuit fixed to the inside of the heat radiation fin (A side) of the semiconductor module. FIG. 26 is a front view of FIG. FIG. 27 is a perspective view showing the structure and wire bonding state of a conductor plate that is vacuum thermocompression bonded to the inside of the radiating fin of the semiconductor module. FIG. 28 is an explanatory view of vacuum-thermocompression bonding of a conductor plate to a heat radiation fin of a semiconductor module via an insulating sheet.

  18 to 21, the semiconductor module 500 according to the present embodiment has a heat radiating fin (A side) 522 on one side (note that the heat radiating fin does not refer only to an uneven fin-shaped portion, but radiates heat. Metal)), the other side radiating fin (B side) 562, the upper and lower arm series circuit 50 sandwiched between the radiating fins 522 and 562, the positive terminal 532 and the negative terminal 572 of the upper and lower arm series circuit, and AC Various terminals including a terminal 582, a top case 512, a bottom case 516, and a side case 508 are provided. As shown in FIGS. 19 and 20, the upper and lower arm series circuit on the conductor plate fixed to the heat radiating fin (A side) 522 and the heat radiating fin (B side) 562 via an insulating sheet (the manufacturing method will be described later). ) Are sandwiched between the radiating fin (A side) 522 and the radiating fin (B side) 562, the bottom case 516, the top case 512, and the side case 508 are attached, and the top case 512 is interposed between the radiating fins 522 and 562. The mold resin is filled from the side to form the semiconductor module 500 as an integrated structure.

  As shown in FIG. 18, the semiconductor module 500 is formed with heat dissipating fins (A side) and heat dissipating fins (B side) facing the cooling water channel. From the top case 512, the positive terminal 532 of the upper and lower arm series circuit 50 is formed. (Corresponding to P terminal 57 in FIG. 2), negative terminal 572 (corresponding to N terminal 58 in FIG. 2), AC terminal 582 (corresponding to AC terminal 59 in FIG. 2), signal terminal (for upper arm) 552, gate In this structure, a terminal (for upper arm) 553, a signal terminal (for lower arm) 556, and a gate terminal (for lower arm) 557 are projected.

  The external appearance of the semiconductor module 500 is a substantially rectangular parallelepiped shape, and the radiation fin (A side) 522 and the radiation fin (B side) 562 are large in area, and the surface of the radiation fin (B side) is the front surface and the radiation fin (A side). Is the rear surface, the side having the side case 508 and the opposite side surfaces, the bottom surface, and the top surface are narrower than the above-described front surface or rear surface. The basic shape of the semiconductor module is a substantially rectangular parallelepiped shape, and the heat radiation fin (B side) and (A side) are square, so that the cutting process is easy, and the semiconductor module is difficult to roll on the production line. There is excellent productivity. Furthermore, the ratio of the heat radiation area with respect to the entire volume can be increased, and the cooling effect is improved.

  In this embodiment, the radiating fin (A side) 522 or the radiating fin (B side) 562 sandwiches the semiconductor chip and holds a conductor inside the semiconductor module and a fin for radiating heat. Is made of one metal. This structure is excellent in increasing the heat dissipation efficiency. However, although the heat radiation efficiency is slightly lowered, a structure in which a semiconductor chip is sandwiched and a metal plate for holding a conductor inside the semiconductor module and a heat radiation fin are separately formed and bonded together can be used.

  Further, a positive terminal 532 (corresponding to the P terminal 57 in FIG. 2), a negative terminal 572 (corresponding to the N terminal 58 in FIG. 2), an AC terminal 582 (in FIG. 2) on the upper surface, which is one of the narrow surfaces of the substantially rectangular parallelepiped shape. ), Signal terminal (for upper arm) 552, gate terminal (for upper arm) 553, signal terminal (for lower arm) 556, and gate terminal (for lower arm) 557. The semiconductor module 500 is excellent in ease of insertion into the water channel housing. Further, as shown in FIG. 18, the outer shape of the upper surface on which such terminals are provided is made larger than the outer shape on the bottom surface side, and the terminal portion that is most easily damaged when the semiconductor module moves on a production line or the like. Can be protected. That is, since the outer shape of the top case 512 is made larger than the outer shape of the bottom case 516, in addition to the effect of being excellent in the sealing performance of the cooling water channel opening described later, when manufacturing or transporting the semiconductor module, the water channel housing There is an effect that the terminal of the semiconductor module can be protected at the time of mounting to the housing.

  According to the arrangement of the terminals described above, the positive electrode terminal 532 and the negative electrode terminal 572 are each arranged so that the cross-sectional area is a rectangular plate shape, and are opposed to each other, and are arranged close to one side surface of the semiconductor module. ing. Since the positive electrode terminal 532 and the negative electrode terminal 572 are arranged on the side surface side, wiring to a capacitor module or the like is facilitated. Further, the connection ends of the positive electrode terminal 532 and the negative electrode terminal 572 and the connection end of the AC terminal 582 are shifted from each other in the front-rear direction of the semiconductor module (the direction connecting both side surfaces of the semiconductor module). For this reason, there is a space for using a tool for connecting the connection end of the positive electrode terminal 532 or the negative electrode terminal 572 and other components and connecting the connection end of the AC terminal 582 and other components in the production line of the power converter. Easy to secure and excellent in productivity.

  There is a possibility that the power conversion device for automobiles is cooled down to minus 30 degrees or less and close to minus 40 degrees. On the other hand, there is a possibility that the temperature may be 100 ° C. or higher, and rarely close to 150 ° C. As described above, in the power conversion device mounted on the automobile, it is necessary to sufficiently consider the change in thermal expansion because the operating temperature range is wide. It is also used in an environment where vibration is constantly applied. The semiconductor module 500 described with reference to FIGS. 18 to 21 has a structure in which a semiconductor chip is sandwiched between two heat dissipating metals. In this embodiment, a metal plate having a heat radiating fin having an excellent heat release function is used as an example of the heat radiating metal. In this embodiment, the heat radiating fin 522 (A side) and the heat radiating fin 562 (B side) will be described. Yes.

  In the structure in which the above-described semiconductor chip is sandwiched, a structure in which both sides of the two heat dissipation metals are fixed by a top case 512 and a bottom case 516 is provided. In particular, the top case 512 and the bottom case 516 have a structure in which the two heat dissipating metals are sandwiched and fixed from the outside. With such a structure, a force is always applied from the outside to the inside of the heat radiating metal, and it is possible to prevent a large force in the direction of opening between the two heat radiating metals from being generated due to vibration or thermal expansion. A highly reliable power conversion device that does not break down even when mounted on a vehicle for a long period of time can be obtained.

  Furthermore, in this embodiment, since the top case 512 and the bottom case 516 including the side case are sandwiched and fixed from the outer peripheral side in addition to the two heat radiating metals, the reliability is further improved. Will improve.

  The positive terminal 532, the negative terminal 572, the AC terminal 582, the signal terminals 552 and 554, and the gate terminals 553 and 556 of the semiconductor module are projected to the outside through holes inside the top case 512 that is one case, This hole is sealed with a mold resin 502. The top case 512 is made of a material having high strength, and is made of a material having a close thermal expansion coefficient, for example, a metal material in consideration of the thermal expansion coefficients of the two heat dissipating metals. The mold resin 502 acts to absorb the stress due to the thermal expansion change of the case 512 and reduce the stress applied to the terminal. For this reason, the power converter of this embodiment has high reliability which can be used even in a state where the range of temperature change is wide as described above or in a state where vibration is constantly applied.

  With reference to FIG. 22 to FIG. 28, a method and structure for forming an upper and lower arm series circuit (two-arm in1 module structure as an example) sandwiched between both heat radiation fins 522 and 562 will be described below.

  A basic process of a semiconductor module manufacturing method according to the present embodiment will be sequentially shown. A heat dissipating metal plate, for example, a heat dissipating fin (A side) 522 and a heat dissipating fin (B side) 562, which are metal plates having a fin structure in the present embodiment, are used as a base material, and an insulating sheet (A side) 524 Insulating sheet (B side) 564 is fixed by vacuum thermocompression bonding (see FIG. 28), and positive electrode side conductor plate 534 and first conductor plate 544 are fixed to insulating sheet 524 (A side) by vacuum thermocompression bonding, A negative conductor plate 574 and an AC conductor plate (second conductor plate) 584 are fixed to the insulating sheet 564 (B side). The fixing of the conductor plates 534 and 544 to the radiating fin (A side) 522 and the insulating sheet (A side) 524 is shown in FIGS. 25 and 26, and the radiating fin (B side) 562 and the insulating sheet (B side) 564 are fixed. The fixing of the conductor plates 574 and 584 is shown in FIG.

  In addition, on the insulating sheet 524 (A side), the signal conductor 554 of the signal terminal (for upper arm) 552, the gate conductor 555 of the gate terminal (for upper arm) 553, the signal terminal (for lower arm) The signal conductor 558 of 556 and the gate conductor 559 of the gate terminal (for lower arm) 557 are fixed. These arrangement relationships are as shown in FIG.

  The insulating sheet (A side) 524 and the insulating sheet (B side) 564 are a semiconductor chip and a conductor, a heat radiation fin (A side) 522, and a heat radiation fin ( (B side) 562 functions as an insulating member that electrically insulates 562 and forms a heat conduction path for conducting heat generated from a semiconductor chip or the like to the radiation fin (A side) 522 or the radiation fin (B side) 562. Work. The insulating member may be a resin insulating sheet or insulating plate, or a ceramic substrate. For example, in the case of a ceramic substrate, the thickness of the insulating member is preferably 350 μm or less, and in the case of an insulating sheet, it is desirable that the thickness is 50 μm to 200 μm. However, in the inductance reduction described later, a thinner insulating member is more effective, and a resin insulating sheet is superior in characteristics to a ceramic substrate.

  Next, IGBT chips 538 and 547 and a diode chip are provided with solder layers 537, 541, 546 and 549 interposed between convex portions 536, 540, 545 and 548 provided on the conductor plates 534 and 544 of the radiation fin (A side) 522. 542 and 550 are soldered (see FIG. 23). At this time, the conductor plate 534 on the positive electrode side and the first conductor plate 544 are provided in an insulated state, and the IGBT chip and the diode chip are soldered to the respective conductor plates 534 and 544. Further, as shown in FIG. 2, a connection plate 594 connecting the emitter electrode of the upper arm and the collector electrode of the lower arm is soldered to the first conductor plate 544 in the same manner as the chips 547 and 550, and the connection plate 594 is The intermediate electrode 69 (see FIG. 2) of the upper and lower arms is configured by abutting connection with the AC conductor plate (second conductor plate) 584.

  Next, between the signal emitter electrode 661 of the IGBT 538 of the upper arm soldered on the conductor plate 534 of the radiation fin (A side) 522 and the signal conductor 554 of the signal terminal (for upper arm) 552, The gate electrode 662 of the IGBT 538 of the upper arm and the gate conductor 555 of the gate terminal (for upper arm) 553 are connected by wire bonding (see FIG. 27). Similarly, the signal emitter electrode of the IGBT 547 of the lower arm and the signal conductor 558 of the signal terminal (for lower arm) 556 soldered onto the first conductor plate 544 of the radiation fin (A side) 522 The gate electrode of the IGBT 547 of the lower arm and the gate conductor 559 of the gate terminal (for lower arm) 557 are connected by wire bonding (see FIG. 27).

  As shown in FIG. 23, both semiconductor chips constituting the upper arm and the lower arm are fixed to the heat radiating fin (A side) 522, which is one of the heat radiating fins, and a signal conductor for controlling signals on these semiconductor chips. 554 and 558 and gate conductors 555 and 559 are provided. Since the semiconductor chip for the upper and lower arms and its control line are fixed to one insulating member in this way, the connection work between the signal line and the semiconductor chip such as wire bonding can be concentrated in the manufacturing process, and the productivity Reliability is improved.

  In addition, when used in an environment with large vibrations, such as for automobiles, vibration resistance is improved because one semiconductor chip to be wired and the other control line are both fixed to one heat radiating fin, which is the same member. To do.

  In the structure shown in FIG. 23, the semiconductor chip for the upper arm and the semiconductor chip for the lower arm are fixed in the same direction, that is, each collector surface is fixed to an insulating sheet 524 as an insulating member. Thus, workability is improved by aligning the direction of the semiconductor chip. The same applies to the diode chip.

  In the structure of FIG. 23, the semiconductor chip for the upper arm and the semiconductor chip for the lower arm are arranged separately on the back side and the front side in the terminal drawing direction. As will be described later, the lead-out direction of the terminal coincides with the insertion direction into the water channel. The semiconductor chip for the upper arm and the semiconductor chip for the lower arm are separately arranged on the back side and the near side in the direction of insertion into the water channel. With such an arrangement, the arrangement of the electrical components in the semiconductor module becomes regular, and the overall size is reduced. In addition, since the heat sources are regularly separated (because each IGBT in the plurality of IGBTs as the heat source operates with regular changes), heat distribution is excellent and the heat radiation surface is regularly separated. Even if the semiconductor module is relatively miniaturized, the heat radiation surface acts effectively and the cooling effect is improved.

  Next, the radiation fin (B side) 562 will be described. A conductive plate that is vacuum-thermocompression bonded to the radiation fin (B side) 562 via an insulating sheet 564 that is an insulating member is fixed. As shown in FIG. 24, an AC conductor plate 584 that pulls out the AC terminal 582 and a negative-side conductor plate 574 that pulls out the negative terminal 572 are disposed in an insulating state on an insulating sheet 564 that is an insulating member. Convex portions 576, 578, 586, and 588 are provided on the conductor plates 574 and 584 as shown in the figure. The convex portions 576 and 586 are connected to the IGBT chip, and the convex portions 578 and 588 are connected to the diode chip.

  In FIG. 24, as shown in the partially enlarged view S1, D1 and D2 represent the thickness of the convex portion, and D1> D2 is because the diode chip is thicker than the IGBT chip. Inside the heat radiation fin (A side) 522, as shown in FIG. 23, the shape in which the emitter electrode of the upper arm and the anode electrode of the diode protrude on the positive conductor plate 534 having the positive terminal 532 is exposed. In addition, the emitter plate of the lower arm and the anode electrode of the diode are projected on the conductor plate 544 and the connection plate 594 constituting the intermediate electrode 69 is projected.

  Subsequently, the radiation fin (A side) 522 and the radiation fin (B side) 562 are opposed to each other as shown in FIG. 22, and the IGBT chips 538 and 547 and the diode chips 542 and 550 of the radiation fin (A side) 522 are arranged. The protrusions 586, 588, 576, and 578 on the conductor plates 574 and 584 of the heat dissipating fin (B side) 562 are faced to each other and soldered so that the electrodes are connected. Further, the connection plate 594 provided on the first conductor plate 544 of the radiating fin (A side) 522 is disposed so as to face the AC conductor plate 584 provided on the radiating fin (B side) 562. Attached. Next, the bottom case 516, the top case 512, and the side case 508 are bonded with an adhesive to the heat radiation fin (A side) 522 and the heat radiation fin (B side) 562 that are integrated (FIG. 20). See). Further, the semiconductor module 500 is formed by filling the mold resin from the hole 513 of the top case.

  As shown in FIGS. 22 and 24, one of the DC terminals and the AC terminal are arranged on one insulating member. In this manner, productivity is improved by adopting a configuration in which wiring members are arranged on the radiation fins (B side) 562 and semiconductor chips are concentrated on the radiation fins (A side) 522.

Further, the positive electrode terminal 532, the negative electrode terminal 572, the AC terminal 582, and the respective conductor plates 534, 574, and 584 inside the semiconductor module are formed as an integrated body, so that productivity is improved. Further, these conductors are each fixed to the heat dissipation metal via an insulating member and sandwich the semiconductor chip. These conductor plates receive forces in the direction in which they are pressed against the heat-dissipating metal by the reaction force from the sandwiched semiconductor chip, and the reliability of the fixing is improved. As described above, since the terminal and each conductor are integrally formed, not only the conductor but also the reliability related to the fixing of the terminal is improved. Therefore, when the semiconductor module having the above structure is applied to an automobile power conversion device, high reliability can be maintained in an environment in which vibration is applied.
Next, the reduction in inductance by the circuit arrangement devised in the semiconductor module according to the present embodiment will be described mainly with reference to FIGS. 34 and 35. FIG. First, before that, a method for attaching a semiconductor chip will be described again with reference to FIGS. 2, 22, 24, and 25. Here, the upper arm will be described. In the radiating fin (A side) 522, the collector and cathode of the semiconductor chip made of IGBT and diode are connected to the conductor plate 534 (Cu lead) of the positive electrode plate that becomes the positive electrode terminal 532 (P terminal). Soldering is performed to expose the emitter electrode of the IGBT and the anode electrode of the diode on the surface of the semiconductor chip. In the heat radiation fin (B side) 562, convex portions 586 and 588 are provided on the AC conductor plate 584 (Cu lead) so as to face the emitter electrode and the anode electrode of the heat radiation fin (A side) 522. An AC terminal 582 (terminal connected to the U-phase, V-phase, or W-phase of the motor generator 92) is provided on an extension of the AC conductor plate 584. Then, when the heat dissipating fin (A side) 522 and the heat dissipating fin (B side) 562 are overlapped and soldered, the circuits of the upper arms 52 and 56 of FIG. 2 are formed, and the AC terminal 582 and the positive terminal 532 are connected to FIG. As shown in FIG. 22, the shape protrudes from the top case 512.

  The above shows the basic structure, but in the present embodiment, in addition to the upper arm (upper semiconductor chip) described above for the radiating fin (A side) 522 and the radiating fin (B side) 562, The lower arm (lower semiconductor chip) is formed in the same manner. As shown in FIG. 23, the IGBT 62 and the diode 66 of FIG. 2 as the lower arm are soldered onto the conductor plate 544 of the heat radiation fin (A side) 522 in the same manner as the upper arm. At this time, the conductor plate of the radiating fin (A side) 522 has two upper and lower stages, and the semiconductor chip of the upper and lower arms is soldered to each stage, and the emitter electrode of the IGBT and the anode electrode of the diode are attached to the surface. Expose. Protrusions 576, 578, 586, and 588 are provided on the conductor plates 574 and 584 of the radiation fin (B side) 562 at positions facing the emitter and anode electrodes of the upper and lower arms of the radiation fin (A side) 522. In addition, a negative electrode terminal 572 is provided on the extended portion of the lower conductive plate 574 and an AC terminal 582 is provided on the extended portion of the upper conductive plate 584.

  With such a structure, the emitter electrode and the anode electrode 542 of the IGBT chip 538 of the upper arm are connected to the AC terminal 582 through the convex portion 586 and the convex portion 588, and the collector electrode and the cathode electrode of the IGBT chip 547 of the lower arm are The conductor plate 544 and the projection-shaped connection plate 594 are connected to the AC conductor plate 584 and communicated with the AC terminal 582. Further, the emitter electrode 547 and the anode electrode 550 of the lower arm pass through the convex portions 576 and 578 and are connected to the negative electrode terminal 572. The circuit configuration shown in FIG. 2 is formed. FIG. 23 shows the abutting surface of the radiating fin (A side) 522, and FIG. 24 shows the abutting surface of the radiating fin (B side) 562. These abutting surfaces are butted together and soldered. Forms the main part.

  As shown in FIGS. 18 to 28, in the power conversion device according to this embodiment, the semiconductor module 500 has a structure in which a semiconductor chip is sandwiched between two heat dissipating metals. In this embodiment, as an example of the heat radiating metal, a metal plate having heat radiating fins having an excellent heat release function, a heat radiating fin 522 (A side) and a heat radiating fin 562 (B side) are used. IGBT chips 538 and 547, which are semiconductor chips, are sandwiched between conductor plates provided inside two heat dissipation metals. With this structure, a low melting point solder can be used as an electrical connection solder. When the low melting point solder is used, the solder may once melt and the semiconductor chip is fixed to one heat dissipation metal, and then the solder portion may be melted again in the process of being sandwiched between the other heat dissipation metal and electrically connected.

  However, as described above, since the fixing method is used in which the both-side electrodes of the semiconductor chip, for example, the collector electrode and the emitter electrode of the IGBT chip are strongly sandwiched in this embodiment, there is a problem that even if the solder layer is melted again, it becomes an obstacle. Does not occur. For this reason, a low melting point solder can be used. Low melting point solder not only has higher productivity than high melting point solder, but also has better thermal conductivity than high melting point solder, and a structure that allows the use of low melting point solder provides a semiconductor module with excellent heat resistance. Therefore, when applied to a power conversion device mounted on an automobile, a great effect can be obtained from the viewpoint of reliability.

  As shown in FIGS. 18 to 28, in the power conversion device according to this embodiment, the semiconductor module 500 has a structure in which a semiconductor chip is sandwiched between two heat dissipating metals. By adopting a structure in which the semiconductor chip is sandwiched between the heat-dissipating metals in this way, it is possible to obtain a power conversion device for automobiles that is always subjected to vibration and can be used in an extremely wide operating temperature range. In the present embodiment, the upper side of the two heat dissipating metals sandwiching the semiconductor chip is fixed by the top case 512, and the positive terminal 532, the negative terminal 572, and the AC terminal 582 of the semiconductor module are exposed to the outside from the top case 512. The semiconductor module has a projecting structure, and has a portion where the cross-sectional area of the terminal becomes narrow at the base of the positive terminal 532, the negative terminal 572, and the AC terminal 582 of the semiconductor module projecting outward. The conductors 534, 574, 584 inside the semiconductor module of each terminal are fixed to one or the other heat radiating metal and have a structure resistant to vibration. Further, although not shown in the drawing, by providing a portion having a small cross-sectional area between the terminal protruding outward and the internal conductor, stress from external vibration or stress due to thermal expansion is directly applied to the internal conductor. Is reduced.

  Next, the reduction in inductance of the semiconductor module in the present embodiment will be described with reference to FIGS. 34 and 35. FIG. Since transient voltage rise and large heat generation of the semiconductor chip occur during the switching operation of the upper or lower arm constituting the inverter circuit, it is desirable to reduce the inductance particularly during the switching operation. Since the recovery current of the diode is generated at the time of transition, the action of inductance reduction will be described based on the recovery current as an example of the recovery current of the diode 66 of the lower arm.

  The recovery current of the diode 66 is a current that flows though the diode 66 is reverse-biased and is generally said to be caused by carriers filled in the diode 66 in the forward state of the diode 66. Three-phase alternating current power is generated at the alternating current terminal of the inverter circuit by conducting the conduction operation or the interruption operation of the upper or lower arm constituting the inverter circuit in a predetermined order. When the semiconductor chip 52 operating as the upper arm is switched from the conductive state to the cut-off state, a return current flows through the lower arm diode 66 in a direction to maintain the current of the stator winding of the motor generator 92. This return current is a forward current of the diode 66, and the inside of the diode is filled with carriers. Next, when the semiconductor chip 52 operating as the upper arm is switched from the cut-off state to the conductive state again, the recovery current caused by the carrier described above flows through the diode 66 of the lower arm. In steady operation, one of the upper and lower arm series circuits is always in the cut-off state, and no short-circuit current flows through the upper and lower arms, but transient current, for example, the diode recovery current flows through the series circuit composed of the upper and lower arms. .

  When the IGBT (switching semiconductor element) 52 that operates as the upper arm of the upper and lower arm series circuit in FIGS. 34 and 35 changes from OFF to ON, the negative terminal passes from the positive terminal 532 (57) through the IGBT 52 and the diode 66. The recovery current of the diode 66 flows through 572 (58) (indicated by an arrow in the figure). At this time, the IGBT 62 is in a cut-off state. Looking at the flow of this recovery current, as shown in FIG. 34, the conductor plates are arranged in parallel near the positive terminal 532 and the negative terminal 572, and the same current in the opposite direction flows. As a result, the magnetic fields generated by the mutual currents cancel each other in the space between the conductor plates, and as a result, the inductance of the current path decreases.

  That is, since the positive conductor 534 and the terminal 532 and the negative conductor 574 and the terminal 572 are in close proximity to each other and arranged in opposition to each other, an effect of reducing inductance occurs. FIG. 35 is an equivalent circuit of FIG. 34, in which the positive side conductor 534 and the equivalent coil 712 of the terminal 532 act together with the negative side conductor 574 and the equivalent coil 714 of the terminal 572 in a direction to cancel the magnetic flux, thereby reducing the inductance. The

  Further, looking at the recovery current path shown in FIG. 34, a loop-shaped path is generated following the reverse and parallel current path. When current flows through the loop-shaped path, eddy currents 605 and 606 flow through the radiating fin (A side) and the radiating fin (B side), and the inductance of the loop-shaped path is reduced by the magnetic field cancellation effect due to the eddy current. Reduction effect occurs. In the equivalent circuit of FIG. 35, the phenomenon of generating an eddy current is equivalently expressed by inductances 722, 724, and 726. Since these inductances are arranged close to the metal plate, which is a heat radiating fin, the eddy current generated by induction cancels out the magnetic flux generated. As a result, the inductance of the semiconductor module is reduced by the eddy current effect. It becomes.

  As described above, the arrangement of the circuit configuration of the semiconductor module according to the present embodiment can reduce the inductance by the effect of the laminate arrangement and the effect of the eddy current. It is important to reduce the inductance during the switching operation, and in the semiconductor module of this embodiment, the series circuit of the upper arm and the lower arm is accommodated in the semiconductor module. For this reason, the inductance reduction effect in a transitional state is large, such as a reduction in inductance with respect to the recovery current of the diode flowing through the upper and lower arm series circuit.

  If the inductance is reduced, the induced voltage generated in the semiconductor module is reduced, so that a low-loss circuit configuration can be obtained, and the switching speed can be improved due to the small inductance. Further, as will be described later with reference to FIG. 31, when a plurality of semiconductor modules 500 including the upper and lower arm series circuits 50 described above are connected in parallel and connected to each capacitor 90 in the capacitor module 95, the capacity is increased. By reducing the inductance of the semiconductor module 500 itself, the influence of the inductance variation due to the semiconductor module 500 in the power conversion device 100 is reduced, and the operation of the inverter device is stabilized.

  Further, when the motor generator is required to have a large capacity (for example, 400 A or more), the capacitor 90 must also have a large capacity. As shown in FIG. Are arranged in parallel as shown in the figure, the positive terminals 532 and the negative terminals 572 of the individual semiconductor modules and the individual capacitor terminals 96 are connected at equal distances, and the current flowing through the respective semiconductor modules is evenly distributed. Therefore, the operation of a well-balanced, low-loss motor generator can be achieved. Furthermore, the parallel arrangement of the positive electrode terminal and the negative electrode terminal of the semiconductor module allows a low-loss operation to be performed in combination with a reduction in inductance due to a laminating effect.

  Next, the specific content disclosed in the drawings will be described with respect to the configuration example of the power conversion device according to the present embodiment. 18 is a view showing the appearance of the semiconductor module with heat radiation fins according to the present embodiment, FIG. 19 is a cross-sectional view of the semiconductor module as seen from the direction of the dashed line in FIG. 18, and FIG. 20 relates to the present embodiment. It is an expanded view of a semiconductor module, Comprising: It is a figure which shows the various terminals of an up-and-down arm series circuit, a radiation fin, and a case. FIG. 21 is a view of the cross-sectional view taken along the alternate long and short dash line in FIG. FIG. 22 shows soldering of the IGBT chip, the diode chip, and the connection plate installed on the conductive plate of the heat radiation fin (A side) and the convex portion of the conductive plate of the heat radiation fin (B side) in the semiconductor module according to this embodiment. It is an expanded view showing this.

  FIG. 23 shows a specific structure of how to install the IGBT chip, the diode chip, and the connection plate on the conductor plate of the radiating fin (A side), the details of which are as described above. FIG. 24 shows a specific arrangement of the protrusions on the conductor plate of the radiating fin (B side), and the thicknesses D1 and D2 of the protrusions in the partial enlarged view S1 are different as described above. FIG. 25 is a perspective view showing a specific arrangement of the protrusions on the conductor plate of the heat radiating fin (A side), S2 is a partial enlarged display, D3 is the thickness of the protrusion 540, and D4 is the protrusion 536. The thickness D5 represents the thickness of the convex portion 592, and the difference in thickness compensates for differences in the thickness of the diode chip, IGBT chip, and connection plate 594 themselves. FIG. 26 is a front view of FIG. FIG. 27 shows a state in which the conductor plate of the radiating fin (A side) and the conductor plate of the radiating fin (B side) overlap, the emitter electrode terminal 661 and the date electrode terminal 662 in the IGBT of the upper and lower arm series circuit, and the signal conductor 554. FIG. 6 is a diagram showing a wire bonding state with a gate conductor 555. FIG. 28 is a diagram showing that the insulating sheets 524 and 564 are vacuum-thermocompression bonded to the radiation fins 522 and 562.

  In FIGS. 23 and 27, the emitter electrode 538 of the upper arm 52 has a rectangular shape, and is separated from the rectangular emitter electrode 538 by a signal emitter electrode terminal 661 (reference numeral 55 in FIG. 2). And a gate electrode terminal 662 (corresponding to reference numeral 54 in FIG. 2). As described above, the signal emitter electrode terminal 661 and the signal conductor 554 are wire-bonded, and the gate electrode terminal 662 and the gate conductor 555 are wire-bonded. On the heat radiation fin (B side) 562, a concave AC conductor plate 584 is formed so as to cover the rectangular emitter electrode 538, and the signal emitter electrode terminal 661 and the gate electrode terminal 662 are passed through the recessed portion of the concave portion. Is exposed. In the configuration example shown in FIGS. 23 and 27, a rectangular emitter electrode 538 provided on the radiation fin (A side) 522 and a concave-shaped AC conductor plate 584 provided on the radiation fin (B side) 562. Is shown.

  The emitter electrode 538 and the AC conductor plate 584 shown in the enlarged display diagram surrounded by the dotted line frame shown in FIG. 27 are improved in terms of current capacity and heat dissipation in the shape of the emitter electrode of the IGBT chip. The improvement will be described with reference to FIG. As shown in FIG. 23, a normal IGBT has a substantially square emitter electrode, and a signal emitter electrode terminal 661 and a gate electrode terminal 662 are provided in an outer region of the square, and other electrodes are provided if necessary.

In this case, as shown in FIG. 24, the substantially square emitter electrode and the conductor 574 and the conductor 584 are electrically connected.

  27 and 41, the ratio of the area of the emitter electrode 538 in the IGBT chip 52 is increased. That is, instead of the rectangular shape shown in FIG. 23, the emitter electrode region is recessed so that only the signal emitter electrode 661 and the gate electrode 662 are exposed, and the signal emitter electrode terminal 661 and the gate electrode terminal are formed in the recessed region. 662, and other electrodes are provided if necessary. Further, the conductors 584 and 574 are also provided with a recess so that the enlarged emitter electrode having the recess is electrically connected to the AC conductor plate 584 and the conductor 574, thereby increasing the connection area with the emitter electrode. . By expanding the area of the emitter electrode, the current density of the emitter of the IGBT chip 52 is lowered and the heat dissipation area is increased. Furthermore, the area of the conductor plates 584 and 574 is increased by providing a concave shape on the AC conductor plate 584 and the conductor 574 so as to face the outer edge of the concave shape of the emitter electrode 538 whose area has been increased (see FIG. 24). The conductor plates 584 and 574 for the emitter electrode have shapes corresponding to the emitter electrodes and do not have a concave recess portion, and FIG. 27 and FIG. 41 have a recess portion. ing.

  Next, connection between the semiconductor module and the capacitor module according to the present embodiment will be described with reference to FIGS. 31, 32, and 33. FIG. Here, the capacitor module may be composed of one electrolytic capacitor or film capacitor, but it is desirable to obtain a larger capacity with a small volume, and a plurality of electrolytic capacitors or film capacitors are electrically connected in parallel. Is preferable. A plurality of unit capacitors are connected in parallel, and the outside thereof is covered with a metal excellent in heat dissipation, thereby obtaining a small and highly reliable capacitor module. Compared with film capacitors, electrolytic capacitors generate a large amount of heat and are particularly effective.

  Also, by covering the outside with metal, the unit capacitor in the capacitor module is firmly fixed in the power conversion device, and is resistant to vibration. For example, the vibration of an automobile includes various component frequencies, and the unit capacitor in the capacitor module may resonate. It is desirable that one or a plurality of unit capacitors are firmly fixed in the capacitor module, and further, the capacitor module is firmly fixed in the power converter as will be described later, for example, firmly fixed to a water channel housing.

  FIG. 31 is a diagram showing connection terminals of the capacitor module of the power converter according to the present embodiment, FIG. 32 is a perspective view showing a connection state between the semiconductor module and the capacitor module, and FIG. It is sectional drawing which shows a connection state. In the drawing, 390 is a capacitor module, 96 is a capacitor terminal, 611 is a capacitor positive terminal, 612 is a capacitor negative terminal, 613 is an insulation guide, 533 is a comb tooth of the positive terminal of the semiconductor module, and 573 is a comb of the negative terminal of the semiconductor module. Tooth 630 represents an insertion slot.

  In the illustrated example, the capacitor module 390 is provided with capacitor terminals 96 corresponding to the U phase, V phase, and W phase of the motor. Corresponding to the number of terminals 96, capacitors 90 are respectively provided in the capacitor modules.

  The positive electrode terminal 611 and the negative electrode terminal 612 of the capacitor terminal 96 are configured in a comb-teeth shape as illustrated, similar to the comb-teeth shapes 533 and 573 of the positive electrode terminal 532 and the negative electrode terminal 572 of the semiconductor module 390. By connecting the connection terminals of the capacitor module 390 and the semiconductor module to each other in a comb-teeth shape, welding between the connection terminals and other fixed connections can be facilitated. The terminal of the capacitor module 390 is provided with an insulating guide 613 at the center. The insulating guide 613 insulates the positive terminal 611 and the negative terminal 612 and inserts the insulating guide 613 into the insertion slot 630 of the semiconductor module. Thus, it also provides a connection guide function between the connection terminals of the capacitor module and the semiconductor module.

  In this embodiment, the DC terminal of the capacitor module 390 is provided corresponding to each DC side terminal of the semiconductor module 500, and the inductance between the terminal of the capacitor module 390 and the terminal of the semiconductor module is reduced. As in this embodiment, it is preferable to directly connect the terminals of the capacitor module and the terminals of the semiconductor module from the viewpoint of reducing the inductance, but there may be a situation where the capacitor module and the semiconductor module cannot be placed close to each other. As shown in FIG. 2 and FIG. 3, the capacitor and the upper and lower arm series circuits of the inverter circuit are connected in parallel. For example, a DC bus bar in which a DC positive conductor and a DC negative conductor are arranged facing each other is used. One end of the bus bar may be connected to the positive terminal 611 and the negative terminal 612 of the capacitor module 390, and the other end of the DC bus bar may be connected to the positive terminal 532 and the negative terminal 572 of the semiconductor module. An increase in inductance can be suppressed by placing the conductors as close as possible so that the magnetic fluxes generated by the direct current positive electrode conductor and the direct current negative electrode conductor constituting the direct current bus bar cancel each other.

  When each phase of the inverter circuit is configured by parallel connection of a plurality of upper and lower arm series circuits as shown in FIG. 3, even when the DC bus bar is used, a plurality of parallel-connected multiples constituting each phase is used. It is desirable that the upper and lower arm series circuits are placed in an electrically equal condition. Therefore, it is desirable to provide connection terminals corresponding to the terminals of the semiconductor modules constituting each phase on the semiconductor module side of the DC bus bar, and the shape thereof is as if the terminal 96 in FIG. desirable.

  Next, the cooling state of the semiconductor module according to this embodiment will be described below with reference to FIGS. 29 and 30. FIG. FIG. 29 is a diagram illustrating a cooling water flow of the heat radiation fin (A side) in the semiconductor module according to the present embodiment. FIG. 30 is a diagram illustrating the relationship between the cooling water flow and the circuit configuration in the semiconductor module. In the figure, 622 represents the flow of the upper cooling water in the semiconductor module, and 623 represents the cooling water flow of the lower water in the semiconductor module.

  As described above, in the semiconductor module according to the present embodiment, the upper arm IGBT chip 52 and the diode chip 56 which are the heating elements are arranged in the upper row in the same row, and the lower arm IGBT chip 62 and the diode which are the heating elements. The chips 66 are arranged in the lower row in the same row. Here, the upper stage corresponds to the front side in the insertion direction of the semiconductor module 500 into the cooling water channel, and the lower stage corresponds to the back side in the insertion direction.

  In addition to the function of exchanging heat with the cooling water, the semiconductor module 500 has a function of keeping the cooling water in a laminar flow state and guiding the cooling water in a predetermined direction. In this embodiment, the cooling water normally forms a horizontal flow along the recesses (grooves) of the uneven heat radiation fins. Then, the cooling water 622 flowing into the upper stage absorbs heat generated from the diode chip 56 and the IGBT chip 52 as indicated by the dotted line, and forms a return path passing through the fin recess of the radiation fin (B side) as indicated by the solid line. To do. Similarly, the cooling water 623 flowing into the lower stage absorbs heat generated from the IGBT chip 62 and the diode chip 66 without being affected by heat generated from the upper semiconductor chips 52 and 56. As described above, the water cooling effect is increased by adopting the structure of the semiconductor module in which the semiconductor chips composed of the IGBT chip and the diode chip, which are the heat generating elements, are arranged in different stages.

Next, an outline of the cooling of the semiconductor module according to this embodiment will be described first. As shown in FIGS. 18 and 19, the semiconductor module 500 includes a radiating fin (A side) and a radiating fin (B side) facing the upper and lower arm series circuit 50 including the upper and lower arm semiconductor chips 52, 56, 62, and 66. And inserted into a water channel housing 212 shown in FIGS. 16 and 17. The semiconductor module is configured to be cooled by allowing water to flow on both surfaces of the heat dissipation plate in which the heat dissipation fins are formed in the semiconductor module 500. That is, the semiconductor chip that is a heating element has a double-sided cooling structure that is cooled from both sides of the radiation fin (A side) 522 and the radiation fin (B side) 562 by cooling water.

  Here, looking at the transition of cooling of semiconductor modules, there is a tendency to evolve to single-sided indirect cooling method, single-sided direct cooling method, double-sided indirect cooling method, double-sided direct cooling method, but in the current cooling method, it is a heating element A group of semiconductor elements in which a plurality of switching semiconductor elements (IGBTs) are provided and connected in parallel (to disperse the heat generated by the semiconductor elements) and connected in parallel via grease and an insulating layer on the heat sink Many structures are installed. In this current cooling system, one side cooling is performed by providing a heat sink on one side of the semiconductor element group, and indirect cooling is performed by interposing grease between the semiconductor element group and the heat sink. Grease is originally intended to adhere a conductor plate with an insulating layer (Cu lead for installing a semiconductor element group) to a heat sink. However, since the thickness is not uniform, it must be fastened with screws. is there. Although this grease has good thermal conductivity, there are difficulties in adhesion, uniformity of thickness and insulation.

  In this embodiment, for example, as shown in FIG. 29, FIG. 30 and the like, there are various improvements, so that even with the indirect cooling method using the above-described grease, the heat dissipation effect is improved over the conventional one. In addition, various other effects can be obtained as described above. As described below, since the semiconductor chip is fixed to the metal for heat dissipation via an insulating member, the heat dissipation effect is further improved. As the insulating member, there are a ceramic plate, a resin insulating sheet, and the like, and by fixing to the heat radiating metal through these, the heat conduction characteristics are improved and the heat radiation effect is improved. In contrast to the ceramic plate, the insulating sheet described below is thin, and a greater effect can be obtained.

  The power conversion device according to the embodiment of the present invention cools from both surfaces of the semiconductor module, and without using grease, an insulating sheet is interposed between the heat radiating plate and the conductor plate on which the semiconductor chip is mounted, thereby performing vacuum heat. Adopting a double-sided direct cooling method of crimping, it is possible to improve the cooling performance. In the present embodiment, as described with reference to FIGS. 28 and 23, the heat dissipating insulating sheets 524 and 564 (for example, insulating resin having a thickness of 100 to 350 mm) are replaced with heat dissipating fins (heat dissipating plates) 522 made of Cu or Al. 562 once by vacuum thermocompression bonding, then vacuum thermocompression bonding again between this insulating sheet and conductor plates 534, 544, 574, 584 (eg, Cu leads) having positive and negative electrode terminals 532, 572, etc. A semiconductor chip is attached to the conductor plate by soldering and, as shown in FIG. 29, the semiconductor module 500 is water-cooled through the heat dissipating fins on both sides. At this time, the insulating sheet has excellent properties in terms of adhesion, uniformity of thickness, and insulation as compared with grease.

  Next, a specific configuration of the power conversion device having a cooling function according to the embodiment of the present invention will be described below with reference to FIGS. FIG. 4 is a diagram showing the external shape of the power converter according to the embodiment of the present invention. FIG. 5 is an exploded view of the internal structure of the power converter according to this embodiment. FIG. 6 is a perspective view in which the upper case is removed from the power converter according to the present embodiment. FIG. 7 is a perspective view in which the upper case, the control board 370 incorporating the control circuit 72, and the bus bar assembly are removed from the power converter according to the present embodiment.

  In the drawing, the power conversion apparatus 100 includes a control board 372 in which a plurality of semiconductor modules 500 are mounted in a water channel housing 212, a driver circuit 74 and a driver IC 374 mounted thereon, and a capacitor module 390 (reference numerals shown in FIG. 31). 95) and a bus bar assembly 386, a connector portion 280 including a DC connector 38 and an AC connector 88 (see FIG. 2), a water channel inlet portion 246 and an outlet portion 248, and a lower case 142, the upper case 112, and the cover 132. The bus bar assembly 386 includes a DC bus that connects the DC terminals of the capacitor module 390 and the semiconductor module 500 and the DC connector 38, and an AC bus that connects the AC terminal 582 and the AC connector 88 of the semiconductor module 500. It is a waste.

  Referring to FIGS. 7 and 8, the water channel housing 212 is roughly divided into a main body portion 214 of the water channel housing, a front surface portion 224 of the water channel housing, and a back surface portion 234 of the water channel housing. An outlet 248 is provided. A control circuit connector 373 and a driver IC 374 are mounted on the control board 372. In the example of FIG. 7, the negative terminal 572, the positive terminal 532, and the alternating current terminal 582 of the semiconductor module protrude, and the negative and positive terminals 572 and 532 are connected to the capacitor terminal of the consensus module 390 (FIGS. 6 and 32). See). In the configuration example of FIG. 7, six upper and lower arm series circuits 50 (main circuits of the semiconductor module 500) are filled and correspond to the circuit configuration of the inverter device 40 shown in FIG. That is, two upper and lower arm series circuits are used for each of the U, V, and W phases of the motor, so that the capacity of the motor generator 92 is increased.

  One inverter device 40 shown in FIG. 3 is connected in parallel to the battery 36, each inverter device is connected to a respective motor generator, and two inverter devices for supplying power to the two motor generators are provided in one water channel housing. The structural example accommodated in 212 is shown in FIGS. The configuration examples shown in FIGS. 8, 9, and 10 are not limited to power supply to the two motor generators. FIG. 8 is a configuration example of the two inverter device in the power conversion device according to the present embodiment, and is a perspective view in which the control board 370 incorporating the control circuit 72, the bus bar assembly, and the upper case are removed. FIG. 9 is a configuration example of the two inverter device in the power conversion device according to the present embodiment, and is a perspective view in which the control board 370 incorporating the control circuit 72, the bus bar assembly, the upper case, and the capacitor module are removed. FIG. 10 is a configuration example of the two inverter device in the power conversion device according to the present embodiment, and is a plan view in which the control board 370 incorporating the control circuit 72, the bus bar assembly, the upper case, and the capacitor module are removed. In FIG. 8, the bus bar assembly 386 is disposed above the control board 372 and is disposed between the two sets of capacitor modules 390.

  Referring to FIGS. 8, 9, and 10, two sets of semiconductor modules 500 are inserted into the water channel housing 212 in a state of being rotated 180 degrees. Similarly, the capacitor module 390 is also arranged in a state rotated by 180 degrees. The control board 372 incorporating the driver circuit 74 is disposed between each set of semiconductor modules 500 and formed from one board. The control circuit connector 373 can also be a single component common to the two sets of semiconductor modules. Each phase is driven by one driver IC 374 for the upper and lower arms of each phase, and each phase is composed of two series circuits in which the upper and lower arms are connected in parallel (see FIG. 3). A control signal is supplied simultaneously from one driver IC 374 to the upper and lower arm series circuits connected in parallel.

  A semiconductor switching circuit in which a control board having a driver circuit is disposed at a position opposite to the capacitor module 390 with respect to the AC terminal, and further, upper and lower arms are configured at a position opposite to the capacitor module with respect to the AC terminal. The control terminal of the element is arranged. With this configuration, the electrical connection between the capacitor module 500 and the semiconductor module and the electrical connection relationship between the control terminal and the control board 372 having the driver circuit 74 are in an orderly state, leading to a reduction in the size of the power converter.

  Further, in the power conversion device having two inverter devices, a control board 372 having a driver circuit 74 is arranged in the center as shown in FIG. 10, thereby providing two driver circuits 74 for controlling the two inverter devices. It is possible to provide two control boards 372, leading to a reduction in size of the power conversion device and an improvement in productivity.

  Next, the manner of loading the semiconductor module into the water channel housing and the flow mode of the cooling water in the water channel housing loaded with the semiconductor module in the power conversion device according to the present embodiment will be described below with reference to FIGS. explain.

  FIG. 11 is a cross-sectional view showing a cooling water flow in a water channel housing loaded with a semiconductor module according to this embodiment. FIG. 12 is a cross-sectional view showing a cooling water flow in a water channel housing loaded with a semiconductor module in the two-inverter device shown in FIG. FIG. 13 is a plan view showing the arrangement of the positive terminal, the negative terminal, the AC terminal, the signal terminal, and the gate terminal of the semiconductor module connected in parallel to each phase to the motor generator shown in FIG. FIG. 14 is a developed perspective view of the main body of the water channel housing, the front surface of the water channel housing, and the rear surface of the water channel housing loaded with the semiconductor module. FIG. 15 is a developed cross-sectional view of the main body of the water channel housing, the front surface of the water channel housing, and the rear surface of the water channel housing loaded with the semiconductor module. FIG. 16 is a perspective view showing a state where the semiconductor module is loaded in the water channel housing main body. FIG. 17 is a front view showing a state where the semiconductor module is loaded in the water channel housing main body.

  11 and 12, 212 is a water channel housing, 214 is a main body portion of the water channel housing, 224 is a front surface portion of the water channel housing, 226 is an inlet water channel in the front portion, 227 is a folded water channel in the front portion, and 228 is a front surface. , 234 is a back surface portion of the water channel housing, 236 is a folded water channel of the back surface portion, 246 is an inlet portion, 248 is an outlet portion, and 250 to 255 are water flows, respectively.

  As shown in FIG. 6 and FIG. 14 to be described later, a front-portion inlet water channel 226 and a front-portion outlet water channel 228 are provided between the inlet portion 246 and the outlet portion 248 and the main body portion 214 connected thereto (FIG. 6). 11), the water channel heights of the water channels 226 and 228 correspond to the height of the semiconductor module 500 (see the water guide portion 249 in FIG. 14). Accordingly, the water flow 250 from the inlet portion 246 is highly expanded in the front-portion inlet water passage 226, and the water flows over the entire height of the radiation fins 522 and 526 of the semiconductor module 500 loaded in the main body portion 214. . Referring to the water flows 251, 236, 253, and 227 shown in FIG. 11, the cooling water flows over the entire height of the radiation fin (B side) 562 of the semiconductor module 500 (water flow 251), As a result, it flows over the entire height of the radiation fin (A side) (water flow 253), passes through the folding path 227 of the front portion 224, and becomes a water flow to the next semiconductor module 500. In this way, the semiconductor module 500 is cooled on both sides.

  FIG. 12 shows a structure in which semiconductor modules in two inverter devices are loaded into one water channel housing and cooled, as shown in FIGS. 9 and 10, and one inverter device has six semiconductor modules. 500-1 is used, and six semiconductor modules 500-2 are used for the other inverter devices. As shown in FIG. 12, the semiconductor modules 500-1 and 500-2 are cascaded along the direction of the water flows 251 and 253 of the water channel housing main body 214.

  In the present embodiment, an opening that leads to the water channel is provided in the water channel housing 212, and the semiconductor module 500 is inserted into the opening. By doing in this way, it becomes possible to produce the semiconductor module 500 in an electronic circuit manufacturing line, and to adhere to a water channel housing after performing a necessary inspection, thereby improving productivity and reliability.

  Further, cooling fins having a large area are provided on both sides of the semiconductor module 500, and a water flow is created by the cooling fins. That is, by inserting the semiconductor module 500 into the water channel, a water channel that flows in the opposite direction is formed, and the cooling fin functions not only to dissipate heat but also to create a laminar flow in the opposite direction, thereby forming a water channel. The water channel housing is made by, for example, die-casting, and the water channel interrogation part is formed by the fins of the semiconductor module 500. Therefore, productivity is improved.

  By inserting the semiconductor module 500 into the water channel, a water channel that flows in the opposite direction is formed, and the cross-sectional area of the water channel becomes narrow. If the amount of cooling water fed is the same, for example, the flow rate increases due to the reduced cross-sectional area. For this reason, cooling efficiency increases.

  FIG. 14 shows a state where all six semiconductor modules 500 are loaded in a water channel housing when semiconductor modules are connected in parallel to each phase to the motor generator (see the circuit configuration of FIG. 3). The situation where the semiconductor modules 500 are sequentially loaded into the main body 214 of the water channel housing 212 is shown in FIGS. The main body 214 of the water channel casing is composed of a partition wall 271 that separates the water channel forming unit 270 and the water channel forming unit 270, and the semiconductor module 500 is loaded into the water channel forming unit 270 from above. Adhesive is applied to the upper edge of the top case 512 and / or the water channel forming part 270 of the semiconductor module 500 to fix them together. As shown in the drawing, since the water channel forming portion 270 and the heat radiation fins 522 and 562 of the semiconductor module 500 are substantially the same size, the cooling water flows along the fin depressions.

  As shown in FIG. 14, the front portion 224 of the water channel housing 212 has a water guide portion 249 having substantially the same bulkiness as the water channel forming portion 270 (see FIG. 16) of the main body portion 214 following the water channel inlet portion 246. I have. The water guide 249 forms a substantially uniform water flow over the entire height of the semiconductor module 500.

As shown in FIGS. 14 and 15, the water channel housing 212 is divided into a main body 214, a front surface 224, and a back surface 234, so that the main body has a shape in which a space to be a water channel is open to the front and back sides. Die-casting method using aluminum as a material becomes possible. Also, the front part 224 and the back part 234 can be die-casted, which improves productivity.
FIG. 13 shows an arrangement structure on the water channel housing 212 in the six semiconductor modules 500 when the semiconductor modules are connected in parallel to each phase to the motor generator (see the circuit configuration in FIG. 3). The upper and lower arm series circuit 50 shown in FIG. 3 is arranged as shown in the figure as 50U1 and 50U2 for the U phase, 50V1 and 50V2 for the V phase, and 50WU1 and 50W2 for the W phase. 31 and 32, the capacitor terminal 96 of the capacitor module is arranged in the same direction as the column direction of the positive electrode terminal 532 and the negative electrode terminal 572 of the semiconductor module 500, and the terminals of the semiconductor module and the capacitor module are directly connected to each other. Since they are coupled, the parasitic inductance is small and uniform, and each semiconductor module operates equally and stably.

  In addition, it is important to make the electrical characteristics of a plurality of upper and lower arm series circuits constituting each phase of UVW as equal as possible. For example, it is important to make the electrical characteristics of the direct circuits 50U1 and 50U2 constituting the U-phase circuit as similar as possible. In this embodiment, the semiconductor module 500 that makes the direct circuit 50U1 and the semiconductor module 500 that makes the direct circuit 50U2 The capacitor module is fixed in the same direction with respect to the arrangement of the DC terminals 572 and 532, and the physical relationship between the terminals of the semiconductor module that directly forms the circuit 50U1 and the terminals of the capacitor module connected thereto is directly The relationship is the same as the relationship between the terminals of the semiconductor module that forms the circuit 50U2 and the terminals of the capacitor module connected thereto. Thus, by arranging the capacitor modules along the direction in which the DC terminals are arranged and providing the capacitor terminals, the electrical characteristics of the DC circuits 50U1 and 50U2 connected in parallel can be made substantially equal.

  In this embodiment, the terminals of the semiconductor module and the terminals of the capacitor module are directly connected, but this is the most preferable structure, but it is not always necessary to connect them directly. For example, even if the positive conductor and the negative conductor are connected in close proximity to each other and are connected via, for example, a DC bus bar, the inductance can be suppressed to a very low level.

  The control or detection terminal groups 552, 553, 556, and 557 are arranged so as to be directly connected to the control board 372 shown in FIG. Therefore, the variation component for each phase caused by the wiring between the semiconductor module 500 and the control circuit and driver circuit in the control board 372 is small and uniform. Furthermore, even when another semiconductor module 500 is added to each phase connected in parallel by two semiconductor modules 500 and connected in parallel by three semiconductor modules 500, the third semiconductor module 500 is also shown in FIG. In this case, it is sufficient to simply arrange them in rows, and the additional applicability of the semiconductor module 500 is excellent.

  Next, another configuration example and cooling structure of the semiconductor module according to this embodiment will be described below with reference to FIGS. FIG. 36 is a perspective view showing another configuration example of the semiconductor module according to this embodiment. FIG. 37 is a cross-sectional view showing another configuration example of the semiconductor module according to the present embodiment, as seen from the dotted arrow in FIG. FIG. 38 is a perspective view illustrating the flow of cooling water in another configuration example of the semiconductor module according to this embodiment. FIG. 39 is a cross-sectional view showing the flow of cooling water when another configuration example of the semiconductor module according to this embodiment is loaded in a water-cooled casing. FIG. 40 is another cross-sectional view showing the flow of cooling water in two stages, upper and lower, when another configuration example of the semiconductor module according to this embodiment is loaded in a water-cooled casing.

  The semiconductor module 500 shown in FIGS. 36 and 37 is different from the semiconductor module 500 shown in FIG. 18 in the structure of the radiation fins, specifically, the radiation fin (A side) 522 and the radiation fin (B side) 562. A thick central fin 570 having a thickness d is provided at the central portion of each.

The position of the central fin 570 is a position that vertically separates the upper arm tips 52 and 56 and the lower arm tips 62 and 66 shown in FIG. 2, and this central fin 570 (for example, the thickness d is the thickness of other fins). It provides a function of separating the water flow into two upper and lower stages.

  FIG. 38 schematically shows the flow of cooling water in the radiation fins of the two semiconductor modules 500. The water flow 650 from the water channel inlet 246 (see FIG. 39) flows only into the lower part of the heat dissipating fin (B side) 562 of the first semiconductor module (the lower half of the central fin 570) to form a water flow 651. To do. Next, the water flow 652 rises at the back surface portion 234 of the water channel housing, and the water flow 653 is formed at the upper stage portion (the upper half of the central fin 570) on the same radiation fin (B side) 562 side. Subsequently, the direction of the water flow is changed at the front portion 224 of the water channel housing to form a water flow 654 in the upper portion of the radiation fin (A side) 522, and then the downward flow 655 becomes the same heat radiation fin (A Side) The water flow 656 in the lower part of 522 is formed, and the direction of the water flow 57 is changed at the front portion 224 to cool the next semiconductor module 500.

  39 and 40, the water flow 651 is formed only in the lower part of the radiating fin (B side) of the semiconductor module at the water inlet 246 and does not flow into the upper part. This is due to the guide portion 660 extending to the inlet portion 246 of the portion 224. Further, the water flow flowing through the lower and upper stages is separated by the closeness between the thickness d of the central fin 570 and the wall surface of the main body 214 or the partition wall 271 (see FIG. 17).

  The cooling effect in the case where the power converter is configured by filling the water channel housing shown in FIGS. 39 and 40 with another configuration example of the semiconductor module 500 shown in FIG. 36 will be described below. This will be described in comparison with the flow path of the cooling water in the water channel housing shown in FIG. 14 (the flow path formed corresponding to the total height of the radiation fins of the semiconductor module). As shown in FIG. 38, the flow path cross-sectional area is substantially halved by flowing the cooling water separately to the upper or lower part of the heat radiating fin. If it is assumed that the flow rate of cooling water flowing into the inlet 246 of the water channel housing 212 is constant (due to the large capacity of the cooling water inflow source), it passes through the upper or lower part of the radiation fin. The flow rate of the cooling water is almost doubled. As the flow rate increases, the amount of heat absorbed by the cooling water from the heat dissipating fins also increases in accordance with the flow rate (the amount of heat absorbed by the cooling water increases approximately in proportion to the magnitude of the flow rate within a certain range of the flow rate). That is, when the semiconductor module having the central fin 570 shown in FIG. 36 is employed and the cooling water flow path is formed by time division into the upper stage portion and the lower stage portion, the cooling effect of the semiconductor module is further enhanced.

  As shown in FIG. 39, the water channel housing is divided into the main body portion 214, the front portion 224, and the back portion 234, so that it can be produced by a die-cast manufacturing method and productivity is improved.

  FIG. 42 is another embodiment of FIG. 5 in which the control board 370 of FIG. 5 is arranged at the bottom of the water channel housing. In FIG. 5, the control board 370 having the control circuit 72 is disposed under the cover 132, and a signal is sent from the connector 371 to the control board 372 having the driver circuit 74 through the signal line 76. The control board 370 is cooled by the upper case.

  In FIG. 42, the control board 370 having the control circuit 72 is arranged at the bottom of the water channel casing 214, and the control board 370 is cooled and fixed by using the bottom space by being fixed to the bottom of the water channel casing. In addition to improving the cooling effect, there is an effect of downsizing. In addition, since the control circuit 72 is provided with a control board 370 that is susceptible to noise at the bottom of the water channel housing 214, the terminals of the semiconductor module 500 are disposed on one side of the water channel housing 214 and the other side. By arranging the control board 370, a structure with high reliability against noise is obtained.

10: Hybrid electric vehicle, 12: Front wheel, 14: Front wheel axle, 16: Front wheel side DEF, 18: Transmission, 20: Engine, 22: Power distribution mechanism, 23, 24, 25, 26: Gear, 27, 28, 29, 30: Gear, 36: Battery, 38: DC connector, 40, 42: Inverter device, 44: Inverter circuit, 50: Upper and lower arm series circuit, 50U1: U-phase series circuit, 50U2: U-phase series circuit, 50V1 : V phase series circuit, 50V1: V phase series circuit, 50W1: W phase series circuit, 50W1: W phase series circuit,
52: upper arm IGBT, 53: upper arm collector electrode, 54: upper arm gate electrode terminal, 55: upper arm signal emitter electrode terminal, 56: upper arm diode, 57: positive electrode (P) terminal, 58: Negative electrode (N) terminal, 59: AC terminal, 62: Lower arm IGBT, 63: Lower arm collector electrode, 64: Lower arm gate electrode terminal, 65: Lower arm signal emitter electrode terminal, 66: Lower arm diode, 69: intermediate electrode, 70: control unit, 72: control circuit (built in control board 370), 74: driver circuit (built in control board 372), 76: signal line, 80: detection unit, 82 : Signal line, 86: AC power line, 88: AC connector, 90: capacitor (built in capacitor module 390), 92, 94: motor generator, 95: capacitor Module, 96: capacitor terminals,
DESCRIPTION OF SYMBOLS 100: Power converter, 112: Upper case, 114: Lower opening of upper case, 116: Recess for inlet part, 118: Recess for outlet part, 120: Upper opening of upper case, 122: Recess for connector, 124: Flange 132: Cover, 142: Lower case, 144: Upper opening of the lower case, 146: Recess for inlet, 148: Recess for outlet, 154: Flange,
212: Water channel housing, 214: Main body of the water channel housing, 216: Water channel of the main body, 218: Insertion port, 224: Front portion of the water channel housing, 226: Entrance water channel of the front portion, 227: Folding of the front portion Water channel, 228: outlet channel in front portion, 234: back surface portion of water channel housing, 236: folded water channel in rear surface portion, 246: inlet portion, 248: outlet portion, 249: water guide portion, 250-255: water flow, 270: Water channel forming part, 271: partition, 280: connector part, 370: control board (with built-in control circuit 72), 372: control board (with built-in driver circuit 74), 373: connector (for control circuit), 374: driver IC 386: Bus bar assembly, 390: Capacitor module,
500: Semiconductor module, 502: Mold resin, 504: Recess (capacitor terminal insulating plate holder), 508: Side case, 512: Top case, 513: Hole, 516: Bottom case, 522: Radiation fin (A side), 524 : Insulating sheet (A side), 532: positive electrode terminal, 533: comb tooth shape, 534: conductor plate on the positive electrode side, 536: convex portion, 537: solder layer, 538: IGBT chip (for upper arm), 540: convex Part, 541: solder layer, 542: diode chip (for upper arm), 544: conductor plate, 545: convex part, 546: solder layer, 547: IGBT chip (for lower arm), 548: convex part, 549: solder Layer, 550: diode chip (for lower arm), 552: signal terminal (for upper arm), 553: gate terminal (for upper arm), 554: signal conductor, 55 : Gate conductor (for upper arm), 556: signal terminal (for lower arm), 557: gate terminal (for lower arm), 558: signal conductor (for lower arm), 559: conductor for gate (lower arm) 562: Radiation fin (B side), 564: Insulation sheet (B side), 570: Center fin, 572: Negative electrode terminal, 573: Comb shape, 574: Conductor plate on the negative electrode side, 576: Projection ( 578: convex portion (connected to diode chip), 582: AC terminal, 583: comb tooth shape, 584: conductor plate for AC, 586: convex portion (connected to IGBT chip), 588: convex Part (connected to the diode chip), 592: convex portion (connected to the intermediate electrode of the upper and lower arms), 593: solder layer (connected to the intermediate electrode of the upper and lower arms), 594: connection plate (configures the intermediate electrode of the upper and lower arms),
605, 606: Eddy current, 611: Capacitor positive terminal, 612: Capacitor negative terminal, 613: Insulation guide (capacitor terminal insulating plate), 630: Insertion slot (dent), 622: Upper cooling water flow in the semiconductor module, 623 : Lower cooling water flow in semiconductor module, 650, 651, 652, 653, 654, 655, 656, 657: Water flow, 660: Guide portion, 661: Signal emitter electrode terminal, 662: Gate electrode terminal S1: FIG. S2: Partial enlarged display of FIG. 25, D1: Thickness of convex portion 586, D2: Thickness of convex portion 588, D3: Thickness of convex portion 540, D4: Thickness of convex portion 536, D5: Thickness of the convex portion 592

Claims (9)

A plurality of semiconductor modules including a series circuit of upper and lower arms of an inverter circuit and having a DC positive terminal, a DC negative terminal, and an AC terminal;
A water channel forming body that forms a water channel between adjacent semiconductor modules among the plurality of semiconductor modules;
A capacitor module with a built-in capacitor ;
A bus bar assembly having an AC bus connected to the AC terminal ,
The plurality of semiconductor modules are fixed to the water channel forming body in a positional relationship arranged in parallel,
The capacitor module is disposed such that the side in the longitudinal direction of the capacitor module is parallel to the arrangement direction of the plurality of semiconductor modules,
Each of the plurality of semiconductor modules is arranged such that the DC positive terminal and the DC negative terminal are closer to the capacitor module than the AC terminal,
The capacitor module has a plurality of capacitor terminals arranged along the longitudinal side of the capacitor module;
Wherein the said DC positive terminal and the DC negative terminal of the plurality of semiconductor modules are the connection plurality of respective electrically to the capacitor terminals of the capacitor module,
The bus bar assembly is a power conversion device arranged at a position facing the capacitor module with the DC positive terminal and the DC negative terminal interposed therebetween . The power conversion device according to claim 1,
The capacitor module is disposed between a capacitor-side positive terminal connected to the DC positive terminal, a capacitor-side negative terminal connected to the DC negative terminal, and the capacitor-side positive terminal and the capacitor-side negative terminal. And an insulating member. The power conversion device according to claim 2,
The DC positive terminal, the DC negative terminal, the capacitor-side positive terminal, and the capacitor-side negative terminal are configured by a side surface and a main surface having a larger area than the side surface,
The capacitor side positive terminal is extended to a position where the main surface of the capacitor side positive terminal faces the main surface of the DC positive terminal, and is directly connected to the DC positive terminal,
The capacitor-side negative electrode terminal is a power conversion device in which a main surface of the capacitor-side negative electrode terminal extends to a position facing the main surface of the DC negative electrode terminal and is directly connected to the DC negative electrode terminal. The power conversion device according to any one of claims 1 to 3,
The said capacitor | condenser module is a power converter device fixed to the said water channel formation body. The power conversion device according to any one of claims 1 to 4,
The DC positive terminal and the DC negative terminal of the plurality of semiconductor modules and the plurality of capacitor terminals of the capacitor module have a main surface perpendicular to the arrangement direction of the plurality of semiconductor modules, Power converters connected to each other. The power conversion device according to any one of claims 1 to 5,
Each of the plurality of capacitor terminals has a capacitor side positive terminal connected to the DC positive terminal, and a capacitor side negative terminal connected to the DC negative terminal,
  Regarding the plurality of capacitor terminals, the capacitor-side positive terminal and the capacitor-side negative terminal are alternately arranged along the arrangement direction of the plurality of semiconductor modules. The power conversion device according to claim 6,
The capacitor-side positive terminal and the capacitor-side negative terminal are configured in a plate-like shape having a rectangular cross section, and have a side surface and a main surface having a larger width than the side surface,
The power converter according to claim 1, wherein the main surface of the capacitor-side positive terminal and the main surface of the capacitor-side negative terminal are arranged to face each other along the arrangement direction of the plurality of semiconductor modules. The power conversion device according to any one of claims 1 to 7,
  The direct current positive terminal and the direct current negative terminal of the plurality of semiconductor modules are directly connected to the plurality of capacitor terminals of the capacitor module. The power conversion device according to any one of claims 1 to 7,
The direct current positive terminal and the direct current negative terminal of the plurality of semiconductor modules are connected to the plurality of capacitor terminals of the capacitor module via a direct current bus bar.

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