JP6234537B1 - Power converter - Google Patents

Abstract

It is possible to reduce the thickness of a power conversion device, to improve heat dissipation of electromagnetic induction equipment such as a transformer, and to realize downsizing, high efficiency, and low cost as a power conversion device. In the power conversion device of the present invention, the primary winding 3 and the secondary winding 4 are both flat windings wound in one layer in a spiral shape. A first holding member 7 that insulates the secondary winding 4 from the cores 5 and 6 and exposes and holds the primary winding 3 and the secondary winding 4, a second holding member 8, and the primary An insulating member 9 interposed between the winding 3 and the secondary winding 4 and insulating the primary winding and the secondary winding is provided, and the primary winding 3, the secondary winding 4, and the core 5, At least one of 6 is thermally and structurally connected to the housing by a heat radiating member and a heat radiating plate. [Selection] Figure 1

Description

The present invention relates to a power conversion device such as an inverter, a DC / DC converter, an in-vehicle charger, or the like, which is mounted on an electric vehicle or a hybrid vehicle that uses a motor as one drive source, and is configured by a transformer, a reactor, and the like.

  In power converters such as DCDC converters and in-vehicle chargers mounted on electric vehicles and hybrid vehicles, electromagnetic induction devices are mounted as passive components that perform voltage step-up and step-down operations. This electromagnetic induction device is a transformer, a reactor, a choke coil, or the like, and is used for storing or releasing energy or smoothing a direct current. With regard to such an electromagnetic induction device, it is very important to reduce the size or increase the efficiency of the power conversion device to reduce the size or to have a structure that can efficiently dissipate the heat generated during energization.

  As an electromagnetic induction device for the purpose of downsizing, for example, Patent Document 1 discloses a power supply transformer. In the power transformer of Patent Document 1, a primary winding and a secondary winding are configured in a laminated structure, and the secondary winding is divided into at least two locations in the axial direction of the bobbin surrounding the core with an insulating member therebetween. It is wound.

In addition, as an electromagnetic induction device that provides heat dissipation and reduction in size and thickness, for example, in a sheet type transformer configured using a printed wiring board in Patent Document 2, it is fixed to a storage case by a fixing component and the heat of the transformer is reduced. It is configured to efficiently dissipate heat in the storage case.

JP 2010-183751 A JP 2010-003926 A

  However, in the power transformer of Patent Document 1, since the winding is wound in a multi-layer structure, it is difficult to reduce the height as the transformer, and heat is generated in the inner winding. Since the heat resistance of the power transformer is deteriorated by adding the thermal resistance of the insulation between the windings outside the windings and the windings, there is a problem that prevents miniaturization.

Moreover, in the reactor of patent document 2, although it has the structure which heat-dissipates a core and a coil | winding by metal fixed parts, especially in the printed wiring which comprises a coil part, the contact area with fixed parts is enough. In this case, the heat radiation from the core and the winding is limited to one, so both the core and the winding are affected by thermal interference. There was a problem that miniaturization as an electronic device was hindered.

  An object of the present invention is to solve the above-described problems, and it is possible to reduce the size and cost of the product and reduce the manufacturing cost by ensuring high heat dissipation while being thin. It is an object of the present invention to provide a power converter that can realize high workability.

A power converter according to the present invention is a power converter in which an electromagnetic induction device having a primary winding and a secondary winding that are electromagnetically coupled via a magnetic core is electrically connected to the electromagnetic induction device. In which the primary winding and the secondary winding are both flat windings wound in one layer in a spiral shape, A first holding member and a second holding member that insulate the primary winding and the secondary winding from the core and expose and hold the primary winding and the secondary winding; and the primary winding and An insulating member interposed between the secondary windings to insulate the primary winding from the secondary winding, wherein at least one of the primary winding, the secondary winding, and the core radiates heat; It is thermally connected to the housing by a member and a heat sink.

According to the present invention, since the windings wound in a spiral shape are stacked, it is possible to reduce the thickness of an electromagnetic induction device such as a transformer, and it is possible to reduce the thickness of the power conversion device. Further, since at least the winding part or the core part of the electromagnetic induction device is connected to the housing via the heat radiating member and the heat radiating plate, both the core part and the winding part have high heat dissipation, and as a power conversion device Miniaturization, high efficiency, and low cost can be realized.
Furthermore, the primary winding and the secondary winding of the power induction device are not stacked while being wound around the bobbin, but are configured by stacking already wound windings. Therefore, the work cost can be reduced, and the manufacturing cost associated therewith can be reduced.

It is a perspective view which shows the power converter device by Embodiment 1 of this invention. It is an exploded view of the power converter device of FIG. FIG. 3 is an exploded view of the electromagnetic induction device of FIGS. 1 and 2. It is sectional drawing of the power converter device of FIG. It is sectional drawing of the power converter device of FIG. It is a perspective view which shows the power converter device by Embodiment 1 of this invention. 1 is an overall exploded perspective view of a power conversion device according to a first embodiment of the present invention. It is a perspective view which shows the power converter device by Embodiment 2 of this invention. It is an exploded view of the power converter device of FIG. FIG. 10 is a perspective view of the electromagnetic induction device of FIGS. 8 and 9. It is an exploded view of the electromagnetic induction apparatus of FIG. It is a perspective view which shows the power converter device by Embodiment 3 of this invention. It is an exploded view of the power converter device of FIG. FIG. 14 is an exploded view of the electromagnetic induction device of FIGS. 12 and 13. It is an exploded view of the coil body which comprises the electromagnetic induction apparatus of FIG. It is a side view of the electromagnetic induction apparatus by Embodiment 4 of this invention. It is a side view of the electromagnetic induction apparatus by Embodiment 5 of this invention. It is a side view of the electromagnetic induction apparatus by Embodiment 6 of this invention.

  Hereinafter, each embodiment of the present invention will be described. In each figure, the same or equivalent members and parts will be described with the same reference numerals.

Embodiment 1 FIG.
1 and 6 are perspective views showing a power conversion device according to Embodiment 1 of the present invention, FIG. 2 is an exploded view of the power conversion device of FIG. 1, and FIG. 3 is a power conversion of FIGS. FIG. 4 is an exploded view of the electromagnetic induction device mounted on the apparatus, FIG. 4 is a cross-sectional view of the power conversion device in the aa cross section of FIG. 1, and FIG. 5 is a cross-sectional view of the power conversion device in the bb cross section of FIG. In FIG. 1 and FIG. 6, other components such as a board mounted in the power converter are omitted.

As shown in FIG. 1, a transformer 2 that is an electromagnetic induction device is mounted on a casing 10, and a lid (not shown) on the opposite side of the casing 10 and the casing 10 is coupled and fitted by screw fastening or the like. The power conversion device 1 is configured by forming a sealed structure. On the bottom surface of the housing 10, a flow path such as a metal fin or pipe is provided, and a cooler (not shown) through which a cooling refrigerant such as water and air passes is connected.
As shown in FIG. 3, the transformer 2 which is an electromagnetic induction device includes an I-type core 5 and an E-type core 6 constituting a closed magnetic circuit, and a primary winding 3 arranged so as to surround a middle leg portion 6a of the core 6. And the secondary winding 4, the insulating sheet 9, which is an insulating member that insulates the primary and secondary windings, holds the primary and secondary windings, and insulates between the winding and the core. A coil body 16 including an upper cover 7 as a first holding member and a lower cover 8 as a second holding member.

The I-type core 5 and the E-type core 6 are composed of magnetic parts such as ferrite, and a closed magnetic circuit is formed by abutting the middle leg portion 6a and the side leg portion 6b of the E-type core 6 with the I-type core 5. The
The primary winding 3 and the secondary winding 4 constituting the coil body 16 have center holes 30 and 40 for enclosing the middle leg portion 6a of the E-type core 6, and have a predetermined electrical resistivity, for example. A copper round wire having an insulating enamel coating is formed by winding a predetermined number of turns in a spiral shape, and is laminated with winding exposed portions 3b and 4b partially exposed from the core 6. . When winding the round wire in the vicinity of the central holes 30 and 40 to the outside after winding, an area intersecting with the winding body is generated. In that case, an insulating sheet (not shown) is provided at the contact portion. Intervene.

Moreover, in order to bundle each round wire which comprises the primary winding 3 and the secondary winding 4, the tape 15 is wound in all directions.
Further, the primary winding terminal 3a of the primary winding 3 and the secondary winding terminal 4a of the secondary winding 4 are arranged with a predetermined distance.
The insulating sheet 9 disposed between the windings 3 and 4 is made of a resin material having insulating properties and flexibility, and the bent portions 9a are formed at the ends of the winding exposed portions 3b and 4b. Have.

The upper cover 7 and the lower cover 8 which are holding members of the winding are formed by molding a resin material having insulation properties, have a shape encompassing the windings 3 and 4, and the core 5 , 6 are provided in conformity with the shape of 6.
In addition, openings 7b and 8b are provided at portions overlapping the winding exposed portions 3b and 4b.
Further, the upper cover 7 has a projection 7c for holding the primary winding terminal 3a and the secondary winding terminal 4a of the windings 3 and 4. The coil body 16 constituted by the windings 3 and 4, the upper cover 7, the lower cover 8, and the insulating sheet 9 is joined by an adhesive (not shown) when sandwiched between the upper cover 7 and the lower cover 8. Alternatively, the cover is fixed by providing a fitting structure such as a snap fit, or by fitting or winding a tape.
Further, as shown in FIG. 5, a predetermined insulation distance indicated by a broken line arrow in FIG. 5 is provided between the windings 3 and 4 by the step portions 7d and 8c provided on the upper cover 7 and the lower cover 8 and the insulating sheet 9. Have.

As shown in FIGS. 2 and 4, the casing 10 constituting the power conversion device 1 is provided with a casing protrusion 10 a and a casing protrusion 10 b for fixing the core, and the transformer 2 is mounted on the casing 10. Coil body 1
6 is in contact with the casing convex portion 10a via the secondary winding heat dissipation sheet 11a which is larger than the projected area of the winding exposed portion 4b of the secondary winding 4.
Further, on the upper part of the coil body 16, a primary winding heat dissipating sheet 11 b is mounted on the winding exposed portion 3 b of the primary winding 3, and further on the width dimension than the primary winding heat dissipating sheet 11 b. The winding heat sink 12 having bent portions 12a at both ends and having holes are placed and the heat dissipation sheets 11a and 11b are compressed, and fastening screws are inserted into the holes at both ends of the heat sink. 14 is fastened to the housing 10 together with the coil body.
The heat radiating plate is formed in a shape having a contact portion to the housing convex portion 10a and a mounting hole by bending a metal plate such as aluminum or copper having a predetermined thermal conductivity by press molding. Yes. The heat radiating sheets 11a and 11b have adhesiveness, and are made of a material such as an insulating low hardness silicone resin containing a heat conductive filler having a predetermined thickness.

In the cores 5 and 6, the central hole in the center of the coil body 16 (that is, the central hole 80 in the lower cover (holding member) 8, the central hole 40 in the secondary winding 4, and the central hole 90 in the insulating sheet 9). In the state where the center hole 30 of the primary winding 3 and the center hole 70 of the upper cover (holding member) 7 are abutted with the opposing I core 5 while the middle leg portion 6a of the E core 6 is passed through the core It is wound and temporarily fixed with an adhesive tape (not shown) a plurality of times in the longitudinal direction.
As shown in FIGS. 1 and 2, the E core 6 is mounted on the flat portion of the housing 10 between the housing convex portions 10 a, and the core heat dissipating sheet 11 c is placed on the upper portion of the I core 5. The core is fixed to the housing 10 by mounting the heat radiating plate 13 at the end so as to fit the housing protrusion 10 b and fastening with the fastening screw 14.
The heatsink for the core is configured as a cantilever spring having high strength of stainless steel and iron and having thermal conductivity. The heat dissipating sheet 11c for the core is composed of a low hardness silicone resin having the same thermal conductivity used in the winding part.

  In the present embodiment, as described above and as illustrated, an electromagnetic induction device having a primary winding and a secondary winding electromagnetically coupled by a magnetic core is electrically connected to the electromagnetic induction device. A power conversion device mounted on a casing on which a power converter to be connected is mounted, wherein each of the primary winding and the secondary winding is a flat plate wound in one layer in a spiral shape A first holding member and a second holding member, which are windings, insulate the core from the primary winding and the secondary winding, and hold the primary winding and the secondary winding exposed. An insulating member interposed between the primary winding and the secondary winding to insulate the primary winding from the secondary winding, and the primary winding, the secondary winding, and At least one of the cores is thermally connected to the housing by a heat radiating member and a heat radiating plate. Moreover, the said heat radiating member is a sheet | seat member etc., and the said primary winding and the said secondary winding are comprised by the round wire and the flat wire.

  Further, as described above, as shown in the figure, the present embodiment includes a primary winding and a secondary winding having a central hole in the center and a predetermined number of turns wound in a spiral shape, A magnetic core that forms a closed magnetic circuit while passing through a central central hole of the winding and exposing the winding portion; an insulating member interposed between the windings; and a holding member for the winding portion. A power conversion device in which an electromagnetic induction device is mounted on a housing, wherein at least the winding portion or the core is thermally connected to the housing via a heat radiating member and a heat radiating plate. .

In the power conversion device 1 according to the present embodiment configured as described above, the heat generated in the primary winding 3 when the transformer 2 is driven is heat dissipation sheet 11b for the primary winding, the heat dissipation plate 12 for the winding, Case convex part 1
Conducted in the order of 0a, and efficiently dissipated heat to the casing 10 and the cooler. The heat generated in the secondary winding 4 is conducted in the order of the secondary winding heat dissipating sheet 11a and the casing convex portion 10a, and is efficiently radiated to the casing 10 and the cooler.

Further, the heat generated in the cores 5 and 6 is also radiated through the housing flat portion facing the E core 6, and at the same time, with respect to the upper I core 5, the core radiating sheet 11 c and the core radiating plate 1.
3. Heat can be efficiently radiated to the housing 10 and the cooler via the housing protrusion 10b.
In addition, both the winding and the core are fixed to the heat radiating plates 12 and 13 or the casing 10 while being compressed through the low-hardness adhesive heat radiating sheets 11a, 11b, and 11c. Because it is connected, by having high adhesion, it is possible to eliminate those that become contact thermal resistance such as winding part, core and heat sink, air layer at the contact part between housings, and further higher heat dissipation It becomes possible to have.

In addition, since the heat sink 12 for winding and the heat sink 13 for core are not integrated with each other, they are individually arranged, so that the heat interference through the heat sink in the cores 5 and 6 and the windings 3 and 4 is prevented. The influence can be eliminated and the heat dissipation can be further improved.

  Further, the transformer (electromagnetic induction device) 2 is configured as described above, and the heat generated by the winding portions 3 and 4 and the cores 5 and 6 that are heating elements is efficiently transferred to the casing 10 and the cooler. Since heat can be efficiently radiated, the winding portions 3 and 4 and the cores 5 and 6 can be downsized. As a result, the power conversion device 1 including the transformer (electromagnetic induction device) 2 can be downsized and highly efficient. In addition, the cost can be reduced along with downsizing and high efficiency.

  The primary winding 3 and the secondary winding 4 constituting the transformer (electromagnetic induction device) 2 are formed by winding a round wire in a spiral shape and laminating the primary winding 3 and the secondary winding 4. Therefore, the winding portion is thin, and the winding portion can be thinned compared to the conventional method in which the conductive wire is wound around the bobbin in a plurality of layers. As a result, the power conversion device 1 including the transformer (electromagnetic induction device) 2 can also be reduced in thickness, and the degree of freedom of layout when mounted in an electric vehicle, for example, when mounted in an electric vehicle can be increased.

  The primary winding 3 and the secondary winding 4 are both formed by winding a round wire in a single layer in a single layer, and both the primary winding 3 and the secondary winding 4 have a single layer winding. Compared to the conventional transformer, which is constructed by winding multiple layers of wire around the bobbin, heat is less likely to be generated inside the windings 3 and 4 because of the configuration in which two parts of the wire are laminated. Can be increased. In addition, since each layer is wound, height variation in the stacking direction is suppressed, and electrical characteristics such as leakage inductance and copper loss, and heat dissipation characteristics such as thermal resistance are stabilized, resulting in miniaturization and high efficiency. Realization and cost reduction can be realized, and at the same time, characteristics and quality control become easy.

  In addition, since the coil body 16 is formed by laminating the windings 3 and 4 wound in advance together with the insulating sheet 9 and the upper and lower covers 7 and 8, a plurality of layers of conductive wires are wound around a conventional bobbin. It becomes possible to manufacture easily with respect to the coil body to comprise, and processing time and the cost at the time of a process can be reduced.

Further, by configuring the insulating member between the primary winding 3 and the secondary winding 4 with a planar insulating sheet 9 having a larger projected area than the primary winding 3 and the secondary winding 4, Since it has high insulation properties including creepage distance between windings and can be made thin, the distance between the primary winding 3 and the secondary winding 4 can be extremely shortened. ), The leakage inductance can be reduced, and the loss and efficiency can be improved.
Further, by forming a bent 9a structure at both ends of the insulating sheet 9 on the winding exposed portion side, an insulating distance between the primary winding 3 and the secondary winding 4 can be secured, and the transformer 2 The projected area as the power conversion device 1 can be reduced.

  In addition, although the insulating sheet in this Embodiment is comprised with the resin-made sheet | seat which has insulation and a softness | flexibility, by using the sheet | seat which has an adhesive layer further, and the double-sided tape which has insulation, it is 1 Adhesion between the secondary winding 3 and the secondary winding 4 is improved, and heat dissipation can be improved by actively exchanging heat between the windings 3 and 4. Furthermore, since adhesiveness increases, workability | operativity at the time of comprising the coil body 16 also increases. Further, the coupling degree and leakage inductance as the transformer 2 can be easily adjusted by adjusting the thickness of the insulating sheet.

Further, the upper cover 7 and the lower cover 8 are configured by a region including the primary winding 3 and the secondary winding 4, and openings 7b and 8b are provided at locations corresponding to the winding exposed portions 3b and 4b. Therefore, the windings 3 and 4 can be structurally held, and the heat generated from the windings 3 and 4 can be stably radiated to the housing 10 via the heat radiation sheets 11a and 11b. Is possible. Also,
Since the flanges 7a and 8a are formed in accordance with the cores 5 and 6, when the cores 5 and 6 are attached to the coil body 16, the workability is good and the creepage between the winding and the core Since the distance can be secured, the insulation between the cores 5 and 6 and the windings 3 and 4 can be secured, and the transformer (electromagnetic induction device) 2 and the power converter 1 can be driven stably. It is.

  Further, the upper and lower covers 7 and 8 are provided with stepped portions 7d and 8c for accommodating the primary winding 3 and the secondary winding 4 in the core region, so that the upper and lower covers of the windings 3 and 4 are assembled when the coil body 16 is assembled. It is possible to improve the mountability to 7 and 8 and workability, and also improve the vibration resistance. Further, as shown by the broken line arrows in FIG. 5 between the primary winding 3 and the secondary winding 4, the covers 7 and 8 having the step portions 7d and 8c and the insulating sheet 9 are laminated. Since the distance is ensured by the creeping distances of the stepped portions 7d and 8c and the insulating sheet 9, the insulation between the windings 3 and 4 can be reliably performed, and can be stably driven as a transformer and a power converter. .

Further, since the primary cover terminal 3a and the secondary winding terminal 4a are provided on the upper cover 7 so that the terminal 7a is inserted, positioning can be performed while holding the terminal when the coil body is assembled. The shape of the winding terminal can be stabilized, and the workability is improved.

  Since the primary winding terminal 3a and the secondary winding terminal 4a in the primary winding 3 and the secondary winding 4 are arranged at a predetermined distance so as not to overlap each other, each winding terminal Insulation can be ensured between the transformer and the transformer and the power converter can be driven stably. In the present embodiment, each terminal is wired on the same exposed side of the winding, but may be wired on the opposite winding exposed portion.

The projected area of the secondary winding heat radiation sheet 11a is increased with respect to the secondary winding 4, and 1
By reducing the width of the heat sink 12 for the winding relative to the heat dissipation sheet for the next winding, an insulation distance between the winding and the housing and between the winding and the heat sink can be secured. It can be driven stably.

  Regarding the core, in this embodiment, the side in contact with the housing 10 is an E core and the opposite core is an I core, but the housing side is an I core and the opposite core is the core. E core may be used. In addition to the E core and I core configurations, any two core shapes can be used, such as an E core, EER, PQ core, etc., that can form a closed magnetic circuit while exposing the coil exposed portions 3b, 4b to the coil body. Can be used.

  For the primary winding 3 and the secondary winding 4, a rectangular wire having a rectangular cross section may be used instead of a round wire having a circular cross section. In this case, the thickness when wound around the round wire can be further reduced, and the thickness can be further reduced as an electromagnetic induction device and a power conversion device. In addition, since the effect of work hardening is obtained at the corners more than when round wires at the time of winding, it is possible to stabilize the shape and further stabilize the electrical characteristics and heat dissipation as a transformer. In addition, since the conductor cross section is rectangular, the contact area between the primary and secondary windings when wound and laminated increases the heat exchange between the windings more actively. Higher heat dissipation can be ensured.

  In this embodiment, the winding approaching the casing convex portion is a secondary winding, and the winding approaching the winding heat sink is set as a primary winding. There may be.

With respect to the heat sink 13 for the core, in the present embodiment, a cantilever spring is used as shown in FIGS. 1 and 2, and both fixing of the core and heat dissipation can be achieved, and the number of parts can be reduced. Cost reduction as a transformer. Further, the core heat sink may not be a cantilever spring as shown in FIG. 1, but may be a bent plate 13a provided with a bent portion 13b having a shape for fixing both feet as shown in FIG. 6, or a spring. In the case of a bent plate, it is possible to use an aluminum-based or copper-based metal as a material. In this case, the heat generated from the core can be dissipated from one of the 13 legs by the legs at both ends, that is, the heat dissipating path can be increased by one, the heat dissipating performance can be further increased, and the core can be further miniaturized. Become.
In addition, since the shape matches the core, it is easy and strong to hold, and workability and vibration resistance can be improved.

  In this embodiment, the core heat-dissipating sheet is disposed between the core and the core heat-dissipating plate. However, the amount of heat generated in the core is small, and it is sufficient through the casing 10 that conducts between the cores and contacts the core. If a sufficient heat dissipation property can be ensured, the core heat dissipation sheet may be omitted. In this case, the number of parts can be reduced, and the cost as a power conversion device can be reduced.

  In this embodiment, the core and the housing are directly contacted via the temporary fixing tape. However, a heat radiation sheet may be interposed between the core and the housing. In this case, the contact thermal resistance between the core and the housing can be reduced, and the heat dissipation of the core can be further enhanced. Furthermore, there is an effect as a cushioning material for preventing the core from being chipped due to rubbing between the core and the housing in a vibration environment.

  In this embodiment, a heat dissipation sheet having a low hardness and having an adhesive layer is used as the heat dissipation material, but a heat dissipation sheet having a high hardness may be used. In addition, when insulation does not become a particular problem, or when insulation is possible with the material, heat radiation grease or adhesive may be used as the heat radiation material. In this case, compared to the case of the heat dissipation sheet, the contact thermal resistance between the heat dissipation material, the heating element (core, winding), and the heat dissipation destination component (heat dissipation plate, housing) can be reduced, and the heat dissipation is further improved. I can do it.

  In addition, you may comprise by winding an insulation sheet and an insulation tape around strand conductors, such as a round wire and a flat wire which comprise the primary winding 3 and the secondary winding 4, previously. In this case, the insulating sheet 9 becomes unnecessary and the number of parts can be reduced.

FIG. 7 is an exploded perspective view of the entire power converter. As illustrated in FIG. 7, in addition to the transformer 2, a filter circuit unit 17, a capacitor unit 18, and a reactor unit 19 are mounted in the housing 10, and a water channel portion of the housing so as to surround the transformer 2 and the reactor unit 19. 10d is arranged. A cooling fluid is supplied into the water channel portion 10d from the water channel pipe 10e. Further, in the present embodiment, a plurality of switching elements 23 for configuring a power converter such as a converter that supplies the output power of the transformer 2 to an external device are illustrated in the upper part of the water channel 10d as illustrated in the figure. Mounted on. A board portion 20 that performs wiring and control between components is mounted on the mounted component, and is connected to terminals of the components by soldering or the like. Thereafter, a lid 21 to be joined to the housing 10 is mounted on the upper part of the substrate, and the housing 10 and the lid 21 are fitted by screw tightening or the like. In the power conversion device 1 configured as described above, the water channel portion 10d is disposed so as to surround the transformer 2 and the reactor portion 19 which are main heat generating components, and therefore heat generated from the transformer 2 and the reactor portion 19 is transferred to both sides. Since heat can be radiated more efficiently than the water channel portion 10d and the switching element 23 can also radiate heat, the power conversion device can be reduced in size and cost.

  In this embodiment, the heat sink for the winding and the heat sink for the core are separately installed. However, if thermal interference between the winding and the core is not a particular problem, the heat sink is integrated and configured. Is applicable. In this case, the number of parts can be reduced, and the cost as a power conversion device can be reduced.

  In this embodiment, an insulating sheet is used as an insulating member, but a resin plate (insulating plate) obtained by molding a resin material is also applicable.

Embodiment 2. FIG.
8 is a perspective view showing a power conversion device according to Embodiment 2 of the present invention, FIG. 9 is an exploded view of the power conversion device of FIG. 8, and FIG. 10 is an electromagnetic induction device mounted on the power conversion device. FIG. 11 is an exploded view of the electromagnetic induction device of FIG. 10. In FIG. 8, other components such as a board mounted in the power converter are omitted. The power conversion device 1 according to the second embodiment is different from the power conversion device 1 according to the first embodiment in that the windings, the core, and the heat radiation plate are thermally connected to the housing via a potting material instead of the heat radiation sheet. Different. Other configurations such as a transformer which is an electromagnetic induction device are the same as those in the first embodiment.

As shown in FIGS. 8 and 9, the casing 10 constituting the power conversion device 1 is provided with a protrusion 10 c, and has a small chamber structure in which the transformer 2 can be impregnated with the potting material 22 after being stored. Further, similarly to the first embodiment, housing convex portions 10a and 10b are provided in the region within the protruding portion 10c. In the present embodiment, the small chamber structure is configured by the protrusion 10c of the housing.
The present invention can also be applied by using a hole (not shown) that has been dug in the casing in advance or formed.

As shown in FIG. 10 and FIG. 11, a bent portion 12a in which a metal plate such as aluminum or copper having a predetermined thermal conductivity is formed into a U-shape by press molding or the like on the upper part of the winding of the transformer 2 and the upper part of the core. , 13b and the core heat sink 13 are mounted and fixed by holding members 7 and 8 (not shown).
After the transformer 2 having the winding heat sink 12 and the core heat sink 13 mounted therein is stored in the protruding portion 10c of the housing 10, the potting material 22 is filled with a dispenser device or the like and cured under a predetermined curing condition. Impregnate. The winding and the gap between the core and the housing are determined by the structure of the holding member and the housing (not shown). Alternatively, the core may not be fixed to the coil body, and the core may be in contact with the housing. The potting material 22 is made of a material such as a silicone resin, an epoxy resin, or a urethane resin having predetermined thermal conductivity and insulation. The gap between the winding and the core and the heat sink is filled with a potting material 22 and is structurally and thermally connected. However, in order to more reliably fill the gap, heat dissipation grease or potting is previously provided. Filling with material 22 is also applicable.

The power conversion device 1 of the present embodiment configured as described above has the same effects as those of the first embodiment. In the second embodiment, the heat generated when the transformer 2 is driven is transferred from the primary winding 3 via the potting material 22 -the heat sink for winding 12 -the potting material 22 and the housing projection 10c.
The secondary winding 4 is connected to the casing protrusions 10a and 10b via a potting material, the core is connected to the casing projection 10c via a potting material 22-core heat sink 12-potting material 22, and Since the area in which the core and the winding and the heat dissipation material are in contact with each other is larger than that in the first embodiment, the heat dissipation performance can be higher than that in the first embodiment, and the power converter 1 can be downsized.

Moreover, since the shape of the heat sink 12 for winding and the heat sink 13 for the core is a U-shape, the area facing the housing 10 can be increased, and the heat dissipation is improved, and the mounting area is small. Therefore, the power conversion device can be further downsized.
In addition, since the heat sink is mounted independently for the winding and the core, the influence of thermal interference between the winding and the core can be reduced, and the heat dissipation can be further improved. . Moreover, the cost reduction as the power converter device 1 by size reduction is also possible.
In the present embodiment, the winding and the core are separated. However, when the heat radiation deterioration due to thermal interference does not become a problem, the winding and the core radiation plate can be integrated. In this case, since the number of parts can be reduced, the power converter 1 can be reduced in cost.
In addition, the winding heat dissipation plate 12 and the core heat dissipation plate 13 can also be applied by forming a hole in a metal plate. In this case, the potting material can be easily filled from the hole.

  Further, since the transformer 2 itself is fixed to the casing 10 by hardening the potting material 22, it is not necessary to fix the heat sinks 12 and 13 to the casing 10 in advance as in the first embodiment. The power conversion device 1 can be further reduced in size and cost.

  Further, since the potting material 22 having an insulating property is filled between the winding and the heat sink 12 for the winding, there is no need for a spatial distance having a predetermined insulation distance as in the first embodiment, and the minimum Since insulation is possible with the resin thickness, the mounting area can be reduced, and the power conversion device 1 can be further reduced in size and cost.

Embodiment 3
12 is a perspective view showing a power conversion device according to Embodiment 3 of the present invention, FIG. 13 is an exploded view of the power conversion device of FIG. 12, and FIG. 14 is an electromagnetic induction device mounted on the power conversion device. FIG. 15 is an exploded view of a coil body constituting the electromagnetic induction device of FIG. In FIG. 12, other components such as a board mounted in the power converter are omitted. As shown in FIGS. 12 and 13, the power conversion device 1 according to the third embodiment is similar to the second embodiment except for the internal configuration of the electromagnetic induction device 2. And structurally and thermally connected to the housing.

  As shown in FIG. 14, the electromagnetic induction device 2 mounted in the power conversion device 1 according to the present embodiment is similar to the first embodiment with respect to the coil body 16 configured in advance as in the first embodiment. It is configured such that the core 6 is sandwiched between the cores 5 and the core heat dissipating plate 13 is mounted from the top of the core 5. When the core heat radiating plate 13 is attached to the core 5, the heat radiating member (grease, sheet, adhesive, potting material) is interposed between the two parts. (Not shown)

  As shown in FIG. 15, the coil body 16 constituting the electromagnetic induction device 2 includes a primary winding 3, a secondary winding 4, an insulating plate 25, and a winding heat dissipation plate 12, which are molded resin. It is comprised in the form which is shape | molded and wrapped by 24. The primary winding 3 and the secondary winding are formed by punching a metal flat plate such as copper or aluminum with a press die or the like, and having a rectangular cross section and having a predetermined gap between adjacent metals in the plane. It is configured. The winding is not limited to a structure in which a metal flat plate is punched out by a press die or the like, but can be applied even if it is molded by laser processing or the like. The terminal portions 3a and 4a are both provided on the outer peripheral portion and inner peripheral portion of the winding, and are configured by bending a part of the outer peripheral portion of the sheet metal and the central holes 30 and 40. The insulating plate 25 is a plate formed by molding a resin material having insulating properties. The first protrusion 25a is provided on both the front and back sides, and the primary winding 3 and the secondary winding 4 are provided on the insulating plate 25. When stacking, the windings are housed in the gaps between the protrusions 25a and the positions are determined. In addition, second protrusions 25b are provided on the inner and outer peripheral portions of the insulating plate, and when the primary winding 3 and the secondary winding 4 are disposed on the insulating plate 25, the creepage distance between the windings. The projection height is set so that becomes a predetermined value. When the heat sink 12 for winding is laminated on the primary winding 3, a gap is interposed between the primary winding 3 and a resin having a predetermined thickness. The coil body 16 is integrated by insert molding with a molding resin 24 having predetermined thermal conductivity and insulation in a state where the respective components are laminated. With respect to the molding resin 24 of the coil body 16, a part of the secondary winding is exposed from the molding resin 24 so that the secondary winding 4 facing the casing convex portions 10 a and 10 b of FIG. 13 can come into contact with the potting resin 2. Molded in form. (Not shown)

The power conversion device 1 of the present embodiment configured as described above has the same effects as those of the first and second embodiments. In addition, since the cross-section of the winding is not a round circle but a rectangle, the primary windings 3 and 2
The surface area that the next winding 4 faces increases, and when an alternating current such as a high-frequency rectangular wave flows, the area through which the current accompanying the skin effect flows can be increased, and the current density can be reduced as compared with the round line. It becomes. As a result, the heat loss generated in the winding can be significantly reduced as compared with the winding constituted by the round wire, and the power conversion device 1 can be improved in efficiency, size, and cost. In addition, since the winding cross section is rectangular, the surface area (width) facing each other between the windings can be maintained, the plate thickness can be reduced in a low loss state, and the first embodiment is configured with a round wire. 2, the height of the electromagnetic induction device 2 and the power conversion device 1 can be reduced. Further, since there is a predetermined gap between the adjacent metals of the winding, the magnetic field generated between the primary winding 3 and the secondary winding 4 can be reduced, and the heat generated in the winding can be reduced. Loss can be further reduced. As a result, the power conversion device can be further improved in efficiency, size, and cost.

  In addition, since the winding is made of a sheet metal formed by punching with a mold, the dimensional accuracy can be greatly improved compared to a winding formed by winding a round wire or a rectangular wire in a spiral shape. It is also possible to suppress variations in heat dissipation characteristics and electrical characteristics associated therewith. In addition, since the raw material is a metal flat plate and no equipment is required, the cost can be reduced as the power conversion device 1 as compared with the winding in the round wire and the flat wire configuration. In addition, in order to ensure dimensional accuracy, a process of bundling windings with tape is required when configured with round wires and rectangular wires, but in the case of sheet metal, dimensional accuracy is ensured when it is punched out with a mold. Therefore, the bundling process can be deleted, and the cost can be reduced due to the workability and the reduction in the number of man-hours. In addition, when winding a rectangular wire, if the ratio of the plate width to the plate thickness is increased beyond a certain level, winding becomes extremely difficult, but in the case of a sheet metal configuration, the sheet thickness can be increased by changing the mold shape. Regardless of this, the plate width can be increased and adjustment is easy. The terminal portions 3a and 4a are arranged on the inner peripheral portion and the outer peripheral portion without routing the inner peripheral portion of the winding to the outer peripheral portion, and a part of the sheet metal without joining another metal member for the terminal. As shown in the first and second embodiments, the same winding metal does not overlap each other and insulation measures such as sandwiching an insulation sheet can be eliminated. Thus, cost reduction and workability improvement are possible.

  In addition, since the primary winding 3 and the secondary winding 4 are stacked and arranged with the insulating plate 25 sandwiched therebetween, the insulation between the primary and secondary windings can be easily secured, and power conversion The device 1 can be driven stably. In addition, since the protrusions 25b having a predetermined height are provided on the inner periphery and the outer periphery of the insulating plate, the insulating plate is also used for dielectric breakdown via creepage between the primary winding 3 and the secondary winding 4. The required distance can be ensured without increasing the size of 25 in the plane direction, and the electromagnetic induction device 2 and the power conversion device 1 can be reduced in size. In addition, since the first protrusions 25a are provided on both surfaces on which the windings are arranged, the primary winding 3 and the secondary winding 4 can be positioned, and displacement can be prevented. The dimensional accuracy as the coil body 16 can be improved.

  In addition, when the heat sink 12 for winding is disposed on the primary winding 3, a molding in which a resin having a predetermined thickness is interposed between the primary winding 3 and the gap is filled. The resin 24 can ensure insulation between the primary winding 3 and the winding heat sink 12, stabilizes the drive as the power converter 1, and simultaneously fills the primary winding with the filled molding resin 24. The heat loss generated in the wire 3 is transferred to the winding heat sink 12 through the molding resin 24 and can be efficiently radiated from the winding heat sink 12 to the potting material 22, the casing 10, and the cooler. It becomes. Further, since the secondary winding 4 facing the casing convex portions 10a and 10b in FIG. 13 is molded in such a manner as to be exposed from the molding resin 24, the secondary winding 4 and the potting material 22 come into contact with each other. The heat loss generated in the next winding 4 can be efficiently radiated to the casing convex portions 10a and 10b and the cooler via the potting material 22.

Further, in the electromagnetic induction device 2 according to the present embodiment, the thermal conductivity of the insulating plate 25 of the molded resin that constitutes the coil body 16, the thickness and width of the winding heat dissipation plate, and the primary and secondary windings are configured. By changing the sheet width and thickness of the sheet metal, it is possible to control the heat dissipation such as easily increasing the heat dissipation of the winding.

  In addition, the primary winding 3, the secondary winding 4, the insulating plate 25, and the heat sink 12 for winding are integrated by insert molding with the molding resin 24, and the coil body 16 is configured in advance. In order to assemble the induction device 2, it is only necessary to attach the core and the heat dissipation plate for the core, and the number of man-hours during assembly and workability can be greatly improved, and the assembly cost can be reduced accordingly.

In addition, although the width | variety of the coil body sheet metal shown in FIG. 15 is comprised by the uniform dimension in the whole area | region, it can be comprised even if it changes a width partially. For example, in the region accommodated in the core, the core shape can be reduced by limiting the plate width to a limited value, and the heat loss in the core is reduced. Efficiency and cost reduction are possible. Further, only the sheet metal portions of the terminal portions 3a and 4a are reduced in advance to reduce the terminal width 3a.
When the 4a is joined to the substrate 20 by soldering, the heat capacity can be reduced, the soldering can be stably performed, and workability is improved.

  In the present embodiment, the primary winding and the secondary winding are formed of each layer as the winding configuration, but the present invention can also be applied to a multilayer configuration. For example, when the primary winding and the secondary winding are configured by two layers of parallel wiring, the inner two layers are arranged with the same polarity winding, and the first winding heat sink is arranged between them. Therefore, heat loss generated in the inner two layers of winding without heat generation of the heat sink is transferred to the heat sink via the molding resin, and heat is efficiently dissipated from the heat sink to the potting material, housing, and cooler. Is possible. In addition, by disposing a second heat sink for the winding on the upper part of the uppermost winding, heat loss in the uppermost winding can be efficiently radiated via the second heat sink. It is. (Not shown)

  In the present embodiment, the heat radiating member between the casing and the electromagnetic induction device is made of a potting material. However, the present invention can be applied even if it is made of a heat radiating sheet, heat radiating grease, an adhesive, or the like.

Embodiment 4 FIG.
FIG. 16 is a side view of the electromagnetic induction device 2 mounted in the power conversion device 1 according to the fourth embodiment of the present invention. In FIG. 16, the holding members 7 and 8, the insulating sheet 9, other components such as a board mounted in the power conversion device, and the housing 10 constituting the electromagnetic induction device are omitted.

  As shown in FIG. 16, the winding structure of the transformer 2 mounted in the power conversion device 1 according to the first, second, and third embodiments of the present invention is in the direction in which the cores 5 and 6 overlap as shown in FIG. They are arranged vertically and linearly.

Embodiment 5. FIG.
In the fifth embodiment, as shown in FIG. 17, the winding is bent in the same direction so as to be parallel to the overlapping direction of the cores.

Embodiment 6 FIG.
Further, as shown in FIG. 18, the present invention can also be applied to a configuration in which the left and right windings are bent in opposite directions.

17 and 18, a housing 10 is disposed at both left and right ends of the transformer 2 (not shown), and the opposing windings radiate heat to the housing 10 (not shown) via the potting material 22. Other configurations are the same as those in the second and third embodiments.

  In the power converters 1 of Embodiments 5 and 6 configured as shown in FIGS. 17 and 18, the mounting area of the transformer 2, which is an electromagnetic induction device, is reduced, so that the volume is reduced and the size can be reduced. Become.

  Also, as shown in FIG. 17, by bending the windings on both the left and right sides in the same direction and in the direction in which the board is arranged, there is no need to bend the terminal drawn from the winding, reducing the processing cost, and the terminal Dimensional accuracy can be improved.

Further, as shown in FIG. 18, by forming the windings on the left and right sides in opposite directions, not only the secondary winding 4 but also the primary winding 3 can be opposed to the housing 10. Therefore, both the primary winding 3 and the secondary winding 4 can efficiently dissipate heat to the housing 10 via the potting material 22. Therefore, heat dissipation can be ensured without installing a winding heat dissipation plate in the winding, and the number of parts can be reduced and the cost can be reduced.

  In the present invention, a transformer is configured as an electromagnetic induction device. However, the present invention can also be applied to a reactor and a choke coil.

  In the first and second embodiments, a round wire is used for the winding. However, as in the third embodiment, a sheet metal such as copper or aluminum is punched out into a spiral shape by press molding or laser processing. It is also possible to use a material molded by the above method. In the third embodiment, the sheet metal is configured as a winding, but the present invention can also be applied by using a round wire or a flat wire.

  In the present invention, a single round wire and a rectangular wire are wound in a spiral shape, and the primary winding and the secondary winding are each laminated in one layer, but a plurality of round wires such as two in advance, The present invention can also be applied to a configuration in which rectangular wires are wound at the same time, or one or both of the primary winding and the secondary winding are laminated in a plurality of layers. In this case, the winding cross-sectional area can be increased or paralleled, and loss in the winding can be reduced. As a result, the power conversion device 1 can be realized with high efficiency, high heat dissipation, and miniaturization. In the case of a plurality of layers, it is possible to dissipate the winding loss in each layer to the housing and the cooler by arranging the required number of winding heat sinks between the layers.

  In the present invention, the secondary winding is closer to the bottom surface of the casing and the primary winding is farther away from the casing.

  In the present invention, the embodiments can be appropriately modified and partially omitted within the scope of the invention.

1 power converter, 2 transformer (electromagnetic induction device), 3 primary winding,
3a Primary winding terminal, 3b Winding exposed part, 30 Center hole,
4 Secondary winding, 4a Secondary winding terminal, 4b Winding exposed part,
30 center hole, 5 I core, 6 E core, 6a middle leg,
6b side leg, 7 upper cover (first holding member), 7a collar,
7b opening, 7c protrusion, 7d step, 70 center hole,
8 Lower cover (second holding member), 8a collar, 8b opening,
8c stepped portion, 80 central hole, 9 insulating sheet (insulating member),
9a bent portion, 90 central hole, 10 housing, 10a housing convex portion,
10b Case convex part, 10c Case protrusion part, 10d Water channel part,
10e water pipe, 11a heat dissipation sheet for secondary winding (heat dissipating member),
11b Heat dissipation sheet for primary winding (heat dissipation member),
11c heat dissipation sheet for core (heat dissipating member), 12 heat dissipating plate for winding,
12a bent portion, 13 heat sink for core, 13a bent plate (heat sink),
13b bending part, 14 fastening screw, 15 winding tape,
16 coil body, 17 filter circuit part, 18 capacitor part,
19 reactor section, 20 substrate section, 21 lid,
22 potting material (heat radiating member), 23 switching element,
24 Molded resin, 25 Insulating plate

Claims (19)

An electromagnetic induction device having a primary winding and a secondary winding that are electromagnetically coupled via a magnetic core is a power conversion device mounted on a housing,
Each of the primary winding and the secondary winding is a flat-plate winding wound in one layer in a spiral shape, and insulates the primary winding and the secondary winding from the core. A first holding member and a second holding member for exposing and holding the primary winding and the secondary winding;
An insulating member interposed between the primary winding and the secondary winding to insulate the primary winding from the secondary winding;
At least one of the primary winding, the secondary winding, and the core is thermally and structurally connected to the housing by a heat radiating member and a heat radiating plate.   The power converter according to claim 1, wherein the heat radiating member is a sheet member.   The power converter according to claim 1, wherein the heat radiating member is a potting resin. The power converter according to claim 1, wherein the heat radiating member is grease or an adhesive. 5. The power conversion device according to claim 1, wherein a part of the heat dissipating member is a molded resin.   The power converter according to any one of claims 1 to 5, wherein the primary winding and the secondary winding are constituted by round wires.   The power converter according to any one of claims 1 to 5, wherein the primary winding and the secondary winding are formed of rectangular wires. The power converter according to any one of claims 1 to 5, wherein the primary winding and the secondary winding are made of sheet metal.   The primary winding and the secondary winding, and the first holding member, the second holding member, the insulating member, and the heat sink are molded so that all or part of them are integrated. The power converter according to claim 6, wherein the power converter is provided.   The power converter according to any one of claims 1 to 9, wherein the heat dissipation member is bent.   The power converter according to any one of claims 1 to 10, wherein the electromagnetic induction device is mounted on a convex portion provided inside the casing.   The power conversion device according to claim 1, wherein the insulating member is a sheet member. The power conversion device according to claim 1, wherein the insulating member is a resin plate. The power converter according to any one of claims 1 to 13, wherein an opening is provided in the first holding member and the second holding member.   The first holding member and the second holding member are made of an insulating resin, and the primary winding and the secondary winding between the first holding member and the second holding member are The power converter according to any one of claims 1 to 14, wherein a step is provided in the area to be stored.   The power converter according to any one of claims 1 to 15, wherein the heat radiating plate is individually provided in the core, the primary winding, and the secondary winding.   The power converter according to claim 16, wherein the heat sink of the core is made of a spring material.   18. The power conversion device according to claim 1, wherein the heat dissipation member is fitted and attached to at least one of the first holding member and the second holding member. .   The power converter according to any one of claims 1 to 18, wherein the wire conductors constituting the primary winding and the secondary winding are insulated conductors.

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