JP6258543B2 - Power converter - Google Patents

Description

  The present invention relates to a power converter used for converting DC power into AC power or converting AC power into DC power, and more particularly to a power converter used in a hybrid vehicle or an electric vehicle.

  In general, a power conversion apparatus includes an inverter circuit that receives DC power and generates AC power, and a control circuit for controlling the inverter circuit. In recent years, miniaturization of power conversion devices has been demanded. Especially in the field of hybrid vehicles and electric vehicles, it is desired to be installed outside the passenger compartment, especially in the engine compartment as small as possible, and further downsizing is required in order to improve the ease of installation in vehicles. Yes.

  In addition, the driving time and operating conditions (high output torque conditions) of a motor used as a drive source tend to increase, and the improvement of the reliability of the power converter is also required at the same time.

  An example of improving the reliability of a power conversion device, particularly a welded portion, is disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 2011-13481) and Patent Document 2 (Japanese Patent Laid-Open No. 2011-172401).

  However, the vibration conditions of the power conversion device mounted on the vehicle are severe, and further improvement in connection reliability of internal components of the power conversion device is required.

JP 2011-134413 A JP 2011-172401 A

  The subject of this invention is aiming at the further improvement of the connection reliability of the internal components of a power converter device.

  A power conversion device according to the present invention is connected to a power semiconductor module that converts a direct current into an alternating current, a housing that forms a storage space for storing the power semiconductor module, and an AC terminal of the power semiconductor module by fusion connection. An AC relay bus bar and an AC terminal block connected to the AC terminal of the motor, the AC relay bus bar being supported by the casing via an insulating member, and the AC terminal block being the AC relay It is connected to the bus bar and supported by the housing.

  ADVANTAGE OF THE INVENTION According to this invention, the further improvement of the connection reliability of the internal components of a power converter device can be aimed at.

It is a disassembled perspective view for demonstrating the structure of a power converter device. It is the perspective view decomposed | disassembled into the component in order to demonstrate the whole structure of a power converter device. FIG. 5 is a view of the flow path forming body 12 shown in FIG. 4 as viewed from the bottom side in order to explain the flow path forming body 12. It is a perspective view which shows the external appearance of the power semiconductor module 300a. It is sectional drawing of the power semiconductor module 300a. It is a perspective view which shows the external appearance of the power semiconductor module 300a. FIG. 5 is a cross-sectional view taken along a section D and viewed from the direction E, as in FIG. The cross-sectional view before the fin 305 is pressurized and the thin portion 304A is deformed is shown. FIG. 6 is a perspective view showing a power semiconductor module 300a in which a module case 304 is further removed from the state shown in FIG. FIG. 6B is a cross-sectional view taken along the section D and viewed from the direction E as in FIGS. 4B and 5B. FIG. 7 is a perspective view of a power semiconductor module 300a in which the first sealing resin 348 and the wiring insulating portion 608 are further removed from the state shown in FIG. It is a figure for demonstrating the assembly process of the module primary sealing body 302. FIG. 4 is a perspective view of a capacitor module 500. FIG. 4 is an exploded perspective view for explaining an internal structure of a capacitor module 500. FIG. It is sectional drawing of the power converter device 200 cut | disconnected by the AA surface of FIG. 7 is an exploded perspective view of the driver circuit board 22, the metal base plate 11, and the AC terminal blocks 760 and 761 with the lid 8 and the control circuit board 20 removed. FIG. It is the cross-sectional perspective view cut | disconnected by the surface B of FIG. It is sectional drawing of the power converter device 200 cut | disconnected by the FF surface of FIG. 5 is a perspective view of an AC side relay conductor 802. FIG. FIG. 11 is a perspective view showing an appearance of an AC terminal block 760. It is a perspective view showing the appearance of AC relay bus bar 750. FIG. 6 is a perspective view in which the lid 8, the control circuit board 20, the metal base plate 11, the driver circuit board 22, and the AC terminal blocks 760 and 761 are removed in order to explain the welding connection portions of the power semiconductor modules 300a to 300c and 301a to 301c. is there.

  Next, embodiments of the present invention will be described with reference to the drawings. The power conversion device 200 according to the present embodiment is mainly used for a hybrid vehicle and an electric vehicle. An example of the vehicle system is described in Japanese Patent Application Laid-Open No. 2011-217550. In addition, the power converter device 100 which concerns on this embodiment may be used for another use in order to achieve the effect. For example, it may be used for a home appliance inverter of a refrigerator or an air conditioner for the purpose of improving productivity and cooling performance. Further, the inverter may be used for an inverter for industrial equipment whose use environment is similar to that for a vehicle inverter.

  FIG. 1 is an exploded perspective view of a power conversion device 200 as an embodiment according to the present invention. FIG. 2 is an exploded perspective view disassembled to help understand the configuration housed in the flow path forming body 12 of the power conversion device 200.

  The power conversion device 200 includes a flow path forming body 12 that functions as a case for housing power semiconductor modules 300a to 300c and power semiconductor modules 301a to 301c and a capacitor module 500, which will be described later, and forms a flow path, and a lid 8. . In addition, a case body may be provided separately from the flow path forming body 12 of the present embodiment, and the flow path forming body 12 may be housed in the case.

  The lid 8 accommodates circuit components constituting the power conversion device 200 and is fixed to the flow path forming body 12. A control circuit board 20 on which a control circuit is mounted is disposed on the inside of the lid 8. A first opening 202, a third opening 204 a, a fourth opening 204 b, and a fifth opening 205 are provided on the upper surface of the lid 8. Further, a second opening 203 is provided on the side wall of the lid 8.

  The connector 21 is provided on the control circuit board 20 and protrudes to the outside through the first opening 202. The negative electrode side power line 510 and the positive electrode side power line 512 electrically connect the DC connector 138 and the capacitor module 500 and the like, and project outside through the third opening 203.

  The AC terminal block 760 is connected to the power semiconductor modules 300a to 300c via the AC relay bus bar 750 and protrudes to the outside via the third opening 204a. The AC terminal block 761 is connected to the power semiconductor modules 301a to 301c via the AC relay bus bar 751 and protrudes to the outside via the fourth opening 204b. The AC output terminal 352 of the auxiliary power module 350 protrudes to the outside through the fifth opening 205.

  The direction of the mating surface of the terminal of the connector 21 and the like varies depending on the vehicle type. However, especially when trying to mount on a small vehicle, the mating surface is directed upward from the viewpoint of the size restriction in the engine room and the assembling property. It is preferable to take out. For example, when the power conversion device 200 is disposed above the transmission TM, the workability is improved by projecting toward the opposite side of the transmission TM.

  The lid 8 is made of metal and functions as a case for housing the power semiconductor modules 300a to 300c and 301a to 301c, the driver circuit board 22, the control circuit board 20, and the metal base plate 11.

  The connector 21 protrudes from the storage space of the lid 8 to the outside of the lid 8 through the first opening 202. Thus, since the control circuit board 20 on which the connector 21 is mounted is mounted on the base plate 11, even if a physical force is applied to the connector 21 from the outside, the load on the control circuit board 20 can be suppressed. Therefore, improvement in reliability including durability can be expected.

  The flow path forming body 12 forms openings 400a to 400c and openings 402a to 402c connected to the flow path through which the cooling refrigerant flows. The openings 400a to 400c are closed by the inserted power semiconductor modules 300a to 300c, and the openings 402d to 402f are closed by the inserted power semiconductor modules 301a to 301c.

  In the flow path forming body 12, a storage space 405 for storing the capacitor module 500 is formed in a side portion of a space in which the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c are stored.

  In the capacitor module 500, since the distances between the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c are substantially constant, the circuit constants of the smoothing capacitor and the power semiconductor module circuit are easily balanced in each of the three phases. Thus, the circuit configuration can easily reduce the spike voltage.

  By making the main structure of the flow path of the flow path forming body 12 by casting an aluminum material integrally with the flow path forming body 12, the flow path can increase the mechanical strength in addition to the cooling effect. Moreover, by making it by aluminum casting, the flow path forming body 12 and the flow path have an integral structure, heat conduction is improved, and cooling efficiency is improved. The power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c are fixed to the flow channel to complete the flow channel, and a water leak test is performed on the water channel. When the water leakage test is passed, the work of attaching the capacitor module 500, the auxiliary power module 350, and the substrate can be performed next. As described above, the flow path forming body 12 is disposed at the bottom of the power conversion device 200, and then the work of fixing necessary components such as the capacitor module 500, the auxiliary power module 350, and the substrate can be sequentially performed from the top. Constructed, productivity and reliability are improved.

  The driver circuit board 22 is disposed above the power semiconductor modules 300 a to 300 c and the power semiconductor modules 301 a to 301 c and the capacitor module 500. A base plate 11 is disposed between the driver circuit board 22 and the control circuit board 20. The metal base plate 11 functions as an electromagnetic shield for a circuit group mounted on the driver circuit board 22 and the control circuit board 20, and also releases and cools heat generated by the driver circuit board 22 and the control circuit board 20. Have.

  Further, it acts to increase the mechanical resonance frequency of the control circuit board 20. That is, it is possible to dispose screwing portions for fixing the control circuit board 20 to the base plate 11 at short intervals, shorten the distance between the support points when mechanical vibration occurs, and increase the resonance frequency. it can. For example, since the resonance frequency of the control circuit board 20 can be increased with respect to the vibration frequency transmitted from the transmission, it is difficult to be affected by vibration and the reliability is improved.

  FIG. 3 is an explanatory diagram for explaining the flow path forming body 12 and is a view of the flow path forming body 12 shown in FIG. 2 as viewed from below.

  The flow path forming body 12 is provided with an inlet pipe 13 and an outlet pipe 14 on one side wall 12a. The cooling refrigerant flows in the direction of the flow direction 417 indicated by the dotted line, and flows through the first flow path portion 19 a formed along one side of the flow path forming body 12 through the inlet pipe 13. The second flow path portion 19b is connected to the first flow path portion 19a via the folded flow path portion, and is formed in parallel with the first flow path portion 19a. The third flow path portion 19c is connected to the second flow path portion 19b through the folded flow path portion, and is formed in parallel with the second flow path portion 19b. The fourth flow path portion 19d is connected to the third flow path portion 19c via the folded flow path portion, and is formed in parallel with the third flow path portion 19c. The fifth flow path portion 19e is connected to the fourth flow path portion 19d through the folded flow path portion, and is formed in parallel with the fourth flow path portion 19d. The sixth flow path portion 19f is connected to the fifth flow path portion 19e via the folded flow path portion, and is formed in parallel with the fifth flow path portion 19e. That is, the first flow path portion 19a to the sixth flow path portion 19f form a meandering flow path connected to one.

  The first flow path forming body 441 includes a first flow path section 19a, a second flow path section 19b, a third flow path section 19c, a fourth flow path section 19d, a fifth flow path section 19e, and a sixth flow path section 19f. Form. The first channel portion 19a, the second channel portion 19b, the third channel portion 19c, the fourth channel portion 19d, the fifth channel portion 19e, and the sixth channel portion 19f are all deeper than the width direction. The direction is formed large.

  The seventh flow path portion 19g is connected to the sixth flow path portion 19f and is formed at a position facing the storage space 405 of the capacitor module 500 shown in FIG. The second flow path forming body 442 forms the seventh flow path portion 19g and a ninth flow path portion 19i described later. The seventh flow path portion 19g is formed so that the width direction is larger than the depth direction.

  The eighth flow path portion 19h is connected to the seventh flow path portion 19g and is formed at a position facing an auxiliary power module 350 described later. The eighth flow path portion 19h is connected to the ninth flow path portion 19i. The third flow path forming body 444 forms the eighth flow path portion 19h. The eighth flow path portion 19h is formed so that the depth direction is larger than the width direction. The ninth flow path portion 19i is formed at a position facing the storage space 405 of the capacitor module 500, similarly to the seventh flow path portion 19g. Further, the ninth flow path portion 19 i is connected to the outlet pipe 14.

  An opening 404 connected to one is formed on the lower surface of the flow path forming body 12. The opening 404 is closed by the lower cover 420. A seal member 409 is provided between the lower cover 420 and the flow path forming body 12 to maintain airtightness.

  Further, the lower cover 420 is formed with convex portions 406 a to 406 f that protrude in a direction away from the flow path forming body 12. The convex portions 406a to 406f are provided corresponding to the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c. That is, the convex portion 406a is formed to face the first flow path portion 19a. The convex part 406b is formed to face the second flow path part 19b. The convex part 406c is formed to face the third flow path part 19c. The convex portion 406d is formed to face the fourth flow path portion 19d. The convex part 406e is formed to face the fifth flow path part 19e. The convex portion 406f is formed to face the sixth flow path portion 19f.

  The depth and width of the seventh flow path portion 19g vary greatly from the depth and width of the sixth flow path portion 19f. Further, the ninth flow path portion 19i changes greatly from the depth and width of the eighth flow path portion 19h. The second flow path forming body 442 has straight fins protruding into the seventh flow path portion 19g and the ninth flow path portion 19i so that the flow medium can be rectified and the flow rate can be controlled by changing the large flow path shape. (Not shown) is preferably provided.

  Similarly, the depth and width of the eighth flow path portion 19h vary greatly from the depth and width of the seventh flow path portion 19g. The third flow path forming body 444 is provided with straight fins (not shown) protruding into the eighth flow path portion 19h so that the flow medium can be rectified and the flow rate can be controlled by changing the large flow path shape. Is preferred. However, this is not the case when there is no problem in the rectification of the cooling refrigerant and the management of the flow velocity.

  Detailed configurations of the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c used in the inverter circuit will be described with reference to FIGS. The power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c all have the same structure, and the structure of the power semiconductor module 300a will be described as a representative.

FIG. 4A is a perspective view of the power semiconductor module 300a of the present embodiment. FIG. 4B is a cross-sectional view of the power semiconductor module 300a according to the present embodiment cut along a cross section D and viewed from the direction E.
FIG. 5 is a diagram showing a power semiconductor module 300a in which the screw 309 and the second sealing resin 351 are removed from the state shown in FIG. FIG. 5A is a perspective view, and FIG. 5B is a cross-sectional view taken along the section D and viewed from the direction E as in FIG. 4B. FIG. 5C shows a cross-sectional view before the fin 305 is pressed and the thin portion 304A is deformed.

  6 is a diagram showing a power semiconductor module 300a in which the module case 304 is further removed from the state shown in FIG. 6 (a) is a perspective view, and FIG. 6 (b) is a cross-sectional view taken along the section D and viewed from the direction E as in FIGS. 4 (b) and 5 (b).

  FIG. 7 is a perspective view of the power semiconductor module 300a in which the first sealing resin 348 and the wiring insulating portion 608 are further removed from the state shown in FIG. FIG. 8 is a view for explaining an assembly process of the module primary sealing body 302.

  As shown in FIGS. 6 and 7, the power semiconductor elements (IGBT 328, IGBT 330, diode 156, diode 166) constituting the series circuit of the upper and lower arms are connected by the conductor plate 315 or the conductor plate 318, or by the conductor plate 320 or the conductor plate 319. Therefore, it is fixed by being sandwiched from both sides. The conductor plate 315 and the like are sealed with the first sealing resin 348 with the heat dissipation surface exposed, and the insulating member 333 is thermocompression bonded to the heat dissipation surface. As shown in FIG. 6, the first sealing resin 348 has a polyhedral shape (here, a substantially rectangular parallelepiped shape).

  The module primary sealing body 302 sealed with the first sealing resin 348 is inserted into the module case 304 and sandwiched between the insulating members 333, and is thermocompression bonded to the inner surface of the module case 304 that is a CAN type cooler. The Here, the CAN-type cooler is a cylindrical cooler having an insertion port 306 on one surface and a bottom on the other surface. The space remaining inside the module case 304 is filled with the second sealing resin 351.

  The module case 304 is made of a member having electrical conductivity, such as an aluminum alloy material (Al, AlSi, AlSiC, Al—C, etc.). The insertion port 306 is surrounded by the flange 304B. Further, as shown in FIG. 4 (a), the first heat radiating surface 307A and the second heat radiating surface 307B, which are wider than the other surfaces, are arranged facing each other so as to face these heat radiating surfaces. Each power semiconductor element (IGBT 328, IGBT 330, diode 156, diode 166) is arranged.

The three surfaces that connect the first heat radiation surface 307A and the second heat radiation surface 307B that face each other constitute a surface that is sealed with a narrower width than the first heat radiation surface 307A and the second heat radiation surface 307B, and the other one side surface An insertion port 306 is formed at the bottom. The shape of the module case 304 does not need to be an accurate rectangular parallelepiped, and the corner may form a curved surface as shown in FIG.
By using the metal case having such a shape, even when the module case 304 is inserted into a flow path through which a coolant such as water or oil flows, a seal against the coolant can be secured by the flange 304B. Intrusion into the module case 304 can be prevented with a simple configuration. Further, the fins 305 are uniformly formed on the first heat radiation surface 307A and the second heat radiation surface 307B facing each other. Furthermore, a thin portion 304A having an extremely thin thickness is formed on the outer periphery of the first heat radiating surface 307A and the second heat radiating surface 307B. Since the thin portion 304A is extremely thin to such an extent that it can be easily deformed by pressurizing the fin 305, the productivity after the module primary sealing body 302 is inserted is improved.

  As described above, the gap between the conductor plate 315 and the inner wall of the module case 304 can be reduced by thermocompression bonding of the conductor plate 315 and the like to the inner wall of the module case 304 via the insulating member 333, and the power semiconductor The generated heat of the element can be efficiently transmitted to the fin 305. Further, by providing the insulating member 333 with a certain degree of thickness and flexibility, the generation of thermal stress can be absorbed by the insulating member 333, which is favorable for use in a power conversion device for a vehicle having a large temperature change. .

  Outside the module case 304, a metal DC positive electrode wiring 315A and a DC negative electrode wiring 319A for electrical connection with the capacitor module 500 are provided, and a DC positive electrode terminal 315B and a DC negative electrode terminal 319B are provided at the tips thereof. Are formed respectively. Further, a metallic AC wiring 320A for supplying AC power to the motor generator is provided, and an AC terminal 320B is formed at the tip thereof. In the present embodiment, as shown in FIG. 7, the DC positive wiring 315A is connected to the conductor plate 315, the DC negative wiring 319A is connected to the conductor plate 319, and the AC wiring 320A is connected to the conductor plate 320.

  In addition to the module case 304, metal signal wirings 324U and 324L for electrical connection with the driver circuit are provided, and a signal terminal 325U and a signal terminal 325L are formed at the tip portions thereof. . In the present embodiment, as shown in FIG. 7, the signal wiring 324 </ b> U is connected to the IGBT 328, and the signal wiring 324 </ b> L is connected to the IGBT 328.

The DC positive electrode wiring 315A, the DC negative electrode wiring 319A, the AC wiring 320A, the signal wiring 324U, and the signal wiring 324L are integrally molded as the auxiliary mold body 600 in a state where they are insulated from each other by the wiring insulating portion 608 formed of a resin material. Is done. The wiring insulating portion 608 also acts as a support member for supporting each wiring, and a thermosetting resin or a thermoplastic resin having an insulating property is suitable for the resin material used therefor. Thereby, it is possible to secure insulation between the DC positive electrode wiring 315A, the DC negative electrode wiring 319A, the AC wiring 320A, the signal wiring 324U, and the signal wiring 324L, and high-density wiring is possible.
The auxiliary mold body 600 is fixed to the module case 304 with a screw 309 that passes through a screw hole provided in the wiring insulating portion 608 after being metal-bonded to the module primary sealing body 302 at the connection portion 370. For example, TIG welding or the like can be used for metal bonding between the module primary sealing body 302 and the auxiliary mold body 600 in the connection portion 370.

  The direct current positive electrode wiring 315A and the direct current negative electrode wiring 319A are stacked on each other in a state of facing each other with the wiring insulating portion 608 interposed therebetween, and have a shape extending substantially in parallel. With such an arrangement and shape, the current that instantaneously flows during the switching operation of the power semiconductor element flows oppositely and in the opposite direction. As a result, the magnetic fields produced by the currents cancel each other out, and this action can reduce the inductance. The AC wiring 320A and the signal terminals 325U and 325L also extend in the same direction as the DC positive wiring 315A and the DC negative wiring 319A.

  The connection portion 370 where the module primary sealing body 302 and the auxiliary mold body 600 are connected by metal bonding is sealed in the module case 304 by the second sealing resin 351. Thereby, since a necessary insulation distance can be stably ensured between the connection part 370 and the module case 304, the power semiconductor module 300a can be reduced in size as compared with the case where sealing is not performed.

  As shown in FIG. 7, on the auxiliary module 600 side of the connecting portion 370, the auxiliary module side DC positive connection terminal 315C, the auxiliary module side DC negative connection terminal 319C, the auxiliary module side AC connection terminal 320C, and the auxiliary module side signal connection are provided. Terminals 326U and auxiliary module side signal connection terminals 326L are arranged in a line. On the other hand, on the module primary sealing body 302 side of the connecting portion 370, along one surface of the first sealing resin 348 having a polyhedral shape, an element side DC positive connection terminal 315D, an element side DC negative connection terminal 319D, The element side AC connection terminal 320D, the element side signal connection terminal 327U, and the element side signal connection terminal 327L are arranged in a line. Thus, the structure in which the terminals are arranged in a row in the connection portion 370 facilitates the manufacture of the module primary sealing body 302 by transfer molding.

  Here, the positional relationship of each terminal when the part extending outward from the first sealing resin 348 of the module primary sealing body 302 is viewed as one terminal for each type will be described. In the following description, a terminal constituted by the DC positive electrode wiring 315A (including the DC positive electrode terminal 315B and the auxiliary module side DC positive electrode connection terminal 315C) and the element side DC positive electrode connection terminal 315D is referred to as a positive electrode side terminal. A terminal composed of the DC negative electrode terminal 319B (including the auxiliary module side DC negative electrode connection terminal 319C) and the element side DC negative electrode connection terminal 315D is referred to as a negative electrode side terminal, and AC wiring 320A (AC terminal 320B and auxiliary module side AC connection) The terminal composed of the terminal 320C and the element side AC connection terminal 320D is referred to as an output terminal, and is composed of the signal wiring 324U (including the signal terminal 325U and the auxiliary module side signal connection terminal 326U) and the element side signal connection terminal 327U. Is called the upper arm signal terminal. It refers to a line 324L (including signal terminals 325L and the auxiliary module-side signal connecting terminals 326L) and the terminal constituted by the element-side signal connecting terminals 327L and the signal terminal for the lower arm.

  Each of the terminals protrudes from the first sealing resin 348 and the second sealing resin 351 through the connection portion 370, and each protruding portion from the first sealing resin 348 (element side DC positive electrode connection terminal 315D). , The element side DC negative connection terminal 319D, the element side AC connection terminal 320D, the element side signal connection terminal 327U, and the element side signal connection terminal 327L) are one surface of the first sealing resin 348 having a polyhedral shape as described above. Are lined up in a row. Further, the positive terminal and the negative terminal protrude from the second sealing resin 351 in a stacked state and extend outside the module case 304. With such a configuration, the power semiconductor element and the terminal are connected at the time of mold clamping when the module primary sealing body 302 is manufactured by sealing the power semiconductor element with the first sealing resin 348. It is possible to prevent an excessive stress on the portion and a gap in the mold from occurring. Further, since the magnetic fluxes in the directions canceling each other are generated by the currents in the opposite directions flowing through each of the stacked positive electrode side terminals and negative electrode side terminals, the inductance can be reduced.

  On the auxiliary module 600 side, the auxiliary module side DC positive electrode connection terminal 315C and the auxiliary module side DC negative electrode connection terminal 319C are the DC positive electrode terminal 315B and the tip of the DC positive electrode wiring 315A and the DC negative electrode wiring 319A opposite to the DC negative electrode terminal 319B. It is formed in each part. Further, the auxiliary module side AC connection terminal 320C is formed at the tip of the AC wiring 320A opposite to the AC terminal 320B. The auxiliary module side signal connection terminals 326U and 326L are formed at the distal ends of the signal wirings 324U and 324L opposite to the signal terminals 325U and 325L, respectively.

  On the other hand, on the module primary sealing body 302 side, the element side DC positive connection terminal 315D, the element side DC negative connection terminal 319D, and the element side AC connection terminal 320D are formed on the conductor plates 315, 319, and 320, respectively. The element side signal connection terminals 327U and 327L are connected to the IGBTs 328 and 330 by bonding wires 371, respectively.

  As shown in FIG. 8, the conductor plate 315 on the DC positive side and the conductor plate 320 on the AC output side and the element side signal connection terminals 327U and 327L are connected to a common tie bar 372, and are substantially the same. It is integrally processed so as to have a planar arrangement. To the conductor plate 315, the collector electrode of the IGBT 328 on the upper arm side and the cathode electrode of the diode 156 on the upper arm side are fixed. The conductor plate 320 is fixedly attached with a collector electrode of the IGBT 330 on the lower arm side and a cathode electrode of the diode 166 on the lower arm side. On the IGBTs 328 and 330 and the diodes 155 and 166, the conductor plate 318 and the conductor plate 319 are arranged in substantially the same plane. To the conductor plate 318, the emitter electrode of the IGBT 328 on the upper arm side and the anode electrode of the diode 156 on the upper arm side are fixed. On the conductor plate 319, an emitter electrode of the IGBT 330 on the lower arm side and an anode electrode of the diode 166 on the lower arm side are fixed. Each power semiconductor element is fixed to an element fixing portion 322 provided on each conductor plate via a metal bonding material 160. The metal bonding material 160 is, for example, a low-temperature sintered bonding material including a solder material, a silver sheet, and fine metal particles.

  Each power semiconductor element has a flat plate-like structure, and each electrode of the power semiconductor element is formed on the front and back surfaces. As shown in FIG. 8, each electrode of the power semiconductor element is sandwiched between the conductor plate 315 and the conductor plate 318, or the conductor plate 320 and the conductor plate 319. In other words, the conductor plate 315 and the conductor plate 318 are stacked so as to face each other substantially in parallel via the IGBT 328 and the diode 156. Similarly, the conductor plate 320 and the conductor plate 319 have a stacked arrangement facing each other substantially in parallel via the IGBT 330 and the diode 166. In addition, the conductor plate 320 and the conductor plate 318 are connected via an intermediate electrode 329. By this connection, the upper arm circuit and the lower arm circuit are electrically connected to form an upper and lower arm series circuit. As described above, the IGBT 328 and the diode 156 are sandwiched between the conductor plate 315 and the conductor plate 318, and the IGBT 330 and the diode 166 are sandwiched between the conductor plate 320 and the conductor plate 319, so that the conductor plate 320 and the conductor plate 318 are connected to the intermediate electrode. Connect via H.329. Thereafter, the control electrode 328A of the IGBT 328 and the element side signal connection terminal 327U are connected by the bonding wire 371, and the control electrode 330A of the IGBT 330 and the element side signal connection terminal 327L are connected by the bonding wire 371.

  FIG. 9A is a perspective view of the capacitor module 500. FIG. 9B is an exploded perspective view for explaining the internal structure of the capacitor module 500. The laminated conductor plate 501 includes a negative electrode conductor plate 505 and a positive electrode conductor plate 507 formed of a plate-like wide conductor, and an insulating sheet 550 sandwiched between the negative electrode conductor plate 505 and the positive electrode conductor plate 507. Since the laminated conductor plate 501 cancels out the magnetic flux with respect to the current flowing through the series circuit of the upper and lower arms of each phase, the inductance of the current flowing through the series circuit of the upper and lower arms is reduced.

  The negative power supply terminal 508 and the positive power supply terminal 509 are formed so as to rise from one side of the laminated conductor plate 501 in the longitudinal direction, and are connected to the positive conductor plate 507 and the negative conductor plate 505, respectively. Yes. The auxiliary capacitor terminals 516 and 517 are formed in a state where they are raised from one side of the laminated conductor plate 501 in the longitudinal direction, and are connected to the positive conductor plate 507 and the negative conductor plate 505, respectively.

  The relay conductor portion 530 is formed in a state of being raised from one side in the longitudinal direction of the multilayer conductor plate 501. The capacitor terminals 503a to 503c protrude from the end of the relay conductor portion 530, and are formed corresponding to the power semiconductor modules 300a to 300c. The capacitor terminals 503d to 503f also protrude from the end of the relay conductor portion 530, and are formed corresponding to the power semiconductor modules 301a to 301c. Each of the relay conductor portion 530 and the capacitor terminals 503a to 503c is configured by a laminated state with the insulating sheet 550 interposed therebetween, and low inductance is achieved with respect to the current flowing through the series circuit 150 of the upper and lower arms. Further, the relay conductor portion 530 is configured such that no through hole or the like that prevents the flow of current is formed at all or as few as possible.

  With such a configuration, a reflux current generated during switching between the power semiconductor modules 300a to 300c provided for each phase is likely to flow to the relay conductor portion 530, and is difficult to flow to the laminated conductor plate 501 side. Therefore, heat generation of the laminated conductor plate 501 due to the reflux current can be reduced.

  In the present embodiment, the negative electrode conductor plate 505, the positive electrode conductor plate 507, the battery negative electrode side terminal 508, the battery negative electrode side terminal 509, the relay conductor portion 530, and the capacitor terminals 503a to 503f are integrally formed metal plates. And has the effect of reducing inductance with respect to the current flowing through the series circuit of the upper and lower arms.

  A plurality of capacitor cells 514 are provided below the laminated conductor plate 501. In the present embodiment, three capacitor cells 514 are arranged in a line along one side in the longitudinal direction of the laminated conductor plate 501, and another three capacitor cells 514 are arranged in the other side in the longitudinal direction of the laminated conductor plate 501. A total of six capacitor cells are provided along one side.

  The capacitor cells 514 arranged along the respective sides in the longitudinal direction of the multilayer conductor plate 501 are arranged symmetrically with respect to the dotted line AA shown in FIG. Thereby, when the direct current smoothed by the capacitor cell 514 is supplied to the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c, the current balance between the capacitor terminals 503a to 503c and the capacitor terminals 503d to 503f And the inductance of the laminated conductor plate 501 can be reduced. Moreover, since it can prevent that an electric current flows locally in the laminated conductor board 501, a heat balance can be equalized and heat resistance can also be improved.

  Capacitor cell 514 is a unit structure of a power storage unit of capacitor module 500, and is a film in which two films each having a metal such as aluminum deposited thereon are stacked and wound so that each of the two metals serves as a positive electrode and a negative electrode. Use a capacitor. The electrode of the capacitor cell 514 is manufactured by spraying a conductor such as tin, with the wound shaft surfaces serving as a positive electrode and a negative electrode, respectively.

  The capacitor case 502 includes a storage portion 511 for storing the capacitor cell 514, and the storage portion 511 has a substantially rectangular upper surface and lower surface. The capacitor case 502 is provided with fixing means for fixing the capacitor module 500 to the flow path forming body 12, for example, holes 520a to 520h for allowing a screw to pass therethrough. The capacitor case 502 of this embodiment is made of a highly heat conductive resin in order to improve the heat conductivity, but may be made of metal or the like.

  After the multilayer conductor plate 501 and the capacitor cell 514 are accommodated in the capacitor case 502, the multilayer conductor plate 501 is covered except for the capacitor terminals 503a to 503f, the negative power supply terminal 508, and the positive power supply terminal 509. Thus, the filler 551 is filled in the capacitor case 502.

In the present embodiment, the seventh flow path portion 19g and the ninth flow path portion 19i are provided along the longitudinal direction of the storage portion 511 of the capacitor module 500 (see FIG. 3), and the cooling efficiency is improved.
In addition, the capacitor cell 514 is disposed so that one of the electrode surfaces of the capacitor cell 514 is opposed to the inner wall forming the side in the longitudinal direction of the storage portion 511. The inner wall forming the side in the longitudinal direction of the storage portion 511 is opposite to the second flow path portion 19b, the third flow path portion 19c, the fourth flow path portion 19d, the fifth flow path portion 19e, and the sixth flow path portion 19f. Formed. As a result, heat is easily transferred in the direction of the winding axis of the film, so that heat easily escapes to the capacitor case 502 via the electrode surface of the capacitor cell 514.

  The noise filter capacitor cell 515a is connected to the positive electrode conductor plate 507 and removes predetermined noise generated between the positive electrode and the ground. The noise filter capacitor cell 515b is connected to the negative electrode conductor plate 505, and removes predetermined noise generated between the negative electrode and the ground. The noise filter capacitor cells 515a and 515b are set to have a smaller capacity than the capacitor cell 514. The noise filter capacitor cells 515a and 515b are disposed closer to the negative power supply terminal 508 and the positive power supply terminal 509 than the capacitor terminals 503a to 503f. Thereby, the predetermined noise mixed in the negative power supply terminal 508 and the positive power supply terminal 509 can be removed early, and the influence of noise on the power semiconductor module can be reduced.

  FIG. 10 is a cross-sectional view of the power conversion device 200 cut along the AA plane in FIG. 1.

  The power semiconductor module 300b is accommodated in the second flow path portion 19b shown in FIG. The outer wall of the module case 304 is in direct contact with the cooling refrigerant flowing in the second flow path portion 19b. The other power semiconductor modules 300a and 300c and the power semiconductor modules 301a to 301c are also housed in the respective flow path portions, similarly to the power semiconductor module 300b.

  The power semiconductor module 300b is disposed on the side of the capacitor module 500. The height 540 of the capacitor module is formed smaller than the height 360 of the power semiconductor module. Here, the height 540 of the capacitor module is the height from the bottom surface of the capacitor case 502 to the capacitor terminal 503b, and the height 360 of the power semiconductor module is the height from the bottom surface of the module case 304 to the tip of the signal terminal 325U. That's it.

  The second flow path forming body 442 includes a seventh flow path portion 19g and a ninth flow path portion 19i that are disposed below the capacitor module 500. That is, the seventh flow path portion 19g and the ninth flow path portion 19i are arranged side by side with the capacitor module 500 along the height direction of the power semiconductor module 300b. The height 443 of the seventh flow path portion is smaller than the difference between the height 360 of the power semiconductor module and the height 540 of the capacitor module. The height 443 of the seventh flow path portion may be the same as the difference between the height 360 of the power semiconductor module and the height 540 of the capacitor module, and the seventh flow path portion 19g and the ninth flow path portion. The height of 19i is the same.

  On the other hand, since the power semiconductor module 300b and the capacitor module 500 can be fixed and connected on the same surface, the assemblability can be improved.

  On the other hand, since the height of the capacitor module 540 is kept lower than the height 360 of the power semiconductor module, the seventh flow path portion 19g can be disposed below the capacitor module 500. Cooling is also possible. Moreover, since the height of the upper part of the capacitor module 500 and the upper part of the power semiconductor module 300b is a short distance, it is possible to suppress the capacitor terminal 503b from becoming longer in the height direction of the capacitor module 500.

  On the other hand, by disposing the seventh flow path portion 19g and the ninth flow path portion 19i in the lower part of the capacitor module 500, it is possible to avoid disposing the cooling flow path on the side of the capacitor module 500, and And the power semiconductor module 300b can be brought close to each other to prevent the wiring distance between the capacitor module 500 and the power semiconductor module 300b from becoming long.

  The driver circuit board 22 is mounted with a transformer 24 that generates drive power for the driver circuit. The height of the transformer 24 is formed larger than the height of the circuit components mounted on the driver circuit board 22. In the space between the driver circuit board 22 and the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c, the signal terminal 325U and the DC positive terminal 315B are arranged. On the other hand, a transformer 24 is disposed in the space between the driver circuit board 22 and the capacitor module 500. Thereby, the space between the driver circuit board 22 and the capacitor module 500 can be effectively used. Further, the distance between the driver circuit board 22 and the metal base plate 11 can be suppressed by mounting circuit components having the same height on the surface of the driver circuit board 22 opposite to the surface on which the transformer 24 is disposed. I can do it.

  FIG. 11 is an overall perspective view in which the lid 8 and the control circuit board 20 are removed and the driver circuit board 22, the base plate 11, and the AC terminal blocks 760 and 761 are disassembled.

  The driver circuit board 22 is disposed on the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c. The metal base plate 11 is disposed on the opposite side of the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c with the driver circuit board 22 interposed therebetween.

  The driver circuit board 22 forms through holes 22a to 22c through which the AC bus bar 763 passes. The driver circuit board 22 forms through holes 22d to 22f through which the AC bus bar 763 passes.

  In the present embodiment, the current sensor 180a is fitted into the through hole 22a, the current sensor 180b is fitted into the through hole 22b, the current sensor 180c is fitted into the through hole 22c, and the current sensor 180d is fitted into the through hole 22d. The current sensor 180e is fitted into the through hole 22e, and the current sensor 180f is fitted into the through hole 22f.

  By providing the through holes 22a to 22f in the driver circuit board 22, the current sensor can be directly arranged on the driver circuit board 22, the wiring of the AC bus bar 763 forming the AC terminal blocks 760 and 761 can be simplified, and the size can be reduced. Contributes to

  The current sensor 180a and the like are disposed in a space between the driver circuit board 22, the power semiconductor modules 300a to 300c, and the power semiconductor modules 301a to 301c. The power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c have DC positive terminals 315B and the like, and these DC positive terminals 315B and the like need to ensure a sufficient insulation distance from the driver circuit board 22.

  By arranging the current sensor 180a and the like in a space for securing the insulation distance, the space in the power converter can be shared with the insulation space and the current sensor arrangement space. Therefore, it leads to size reduction of a power converter device.

  In the base plate 11, a through hole 11a is formed at a position facing the through holes 22a to 22c, and a through hole 11b is formed at a position facing the through holes 22d to 22f. As shown in FIG. 1, the lid 8 forms a third opening 204 a at a position facing the through hole 11 a to form an AC connector 188. Further, the lid 8 forms a fourth opening 204b at a position facing the through hole 11b to form an AC connector 188.

  Accordingly, even when the driver circuit board 22 is disposed between the AC connector 188 and the power semiconductor modules 301a to 301c, the wiring of the AC bus bar 763 forming the AC terminal blocks 760 and 761 is suppressed. The power converter 200 can be downsized.

  The through holes 22 a to 22 c are provided in the driver circuit board 22 along the direction in which the AC bus bars 763 are arranged. Further, the driver circuit board 22 has a length in which the long side of the capacitor module 500 is one side, and the short side of the capacitor module 500 is combined with the long sides of the power semiconductor modules 300a to 300c and 301a to 301c. It has a rectangular shape on the other side.

  Thereby, since the through holes 22a to 22c are arranged along one side of the driver circuit board 22, even if there are a plurality of through holes, a wide circuit wiring area can be secured.

  As shown in FIG. 1, the control circuit board 20 is disposed to face one surface of the lid 8 that forms the first opening 202. The connector 21 is directly mounted on the control circuit board 20 and protrudes to the outside through the first opening 202 formed in the lid 8. Thereby, the space inside the power conversion device 200 can be effectively used.

  In addition, since the control circuit board 20 on which the connector 21 is mounted is fixed to the base plate 11, even if a physical force is applied to the connector 21 from the outside, the load on the control circuit board 20 can be suppressed. The improvement of reliability including durability can be expected.

  12 is a cross-sectional perspective view taken along plane B of FIG. The connection portion 23a is a connection portion between the signal terminal 325U of the power semiconductor module 300a and the driver circuit board 22. The connection portion 23b is a connection portion between the signal terminal 325L of the power semiconductor module 300a and the driver circuit board 22. The connection parts 23a and 23b are formed of a solder material.

  The through hole 11a of the base plate 11 is formed up to a position facing the connecting portions 23a and 23b. Thereby, in the state where the driver circuit board 22 is fixed to the base plate 11, the connection work of the connection portions 23 a and 23 b can be performed through the through holes 11 a of the metal base plate 11.

  The control circuit board 20 is arranged so that the projected part of the control circuit board 20 does not overlap the projected part of the through hole 11a when projected from the upper surface of the power conversion device 200. Thereby, the control circuit board 20 does not interfere with the connection work of the connection parts 23a and 23b, and the control circuit board 20 can reduce the influence of electromagnetic noise from the connection parts 23a and 23b.

  In the present embodiment, the driver circuit board 22 is formed large so as to face the power semiconductor module 300 a and the like and the capacitor module 500. Even in such a case, the AC terminal 320B is disposed farther than the DC positive terminal 315B with respect to the capacitor module 500. The control terminal 325L is disposed between the DC positive terminal 315B and the AC terminal 320B. The connecting portion 23b is disposed at a position facing the control terminal 325L.

  Thus, the through hole 22b is disposed on the driver circuit board 22 closer to the edge of the driver circuit board 22 than the driver circuit 25. Therefore, a decrease in strength of the driver circuit board 22 due to the formation of the through hole 22b can be suppressed, and vibration resistance performance can be improved.

  FIG. 13 is a cross-sectional view of the power conversion device 200 cut along the FF plane in FIG. 1. Both the AC relay bus bar 751 and the AC terminal block 761 are supported by the flow path forming body 12 having a function as a casing. For this reason, the load applied when the AC connector 188 of the motor is attached is stress-dispersed to the flow path forming body 12 in the direction of the arrow direction 755 indicated by the dotted line via the AC terminal block 761. Further, the load that is not distributed and partitioned by the AC terminal block 761 is stress-dispersed from the AC bus bar 763 through the AC relay bus bar 751 to the flow path forming body 12 in the direction of the arrow 756 indicated by the two-dot chain line.

  As a result, the load applied when the AC connector 188 of the motor is attached reaches the AC welding connection portion 751a, so that the stress is distributed in two stages, and the stress generated in the welded portion can be eliminated as much as possible.

  AC relay bus bar 751 is welded to AC terminal 320B of power semiconductor module 301a. The AC terminal block 761 is connected to the AC connector 188 of the motor and also connected to the AC relay bus bar 751. As a result, the effect of reducing the stress generated in the welded portion is maintained by changing only the shape of the AC bus bar 763 forming the AC terminal block 761, and the output direction of the AC connector 188 of the motor is changed to that of the power semiconductor module 301a. A structure capable of both the upper surface direction and the side surface direction can be easily adopted.

  The metal support member 803 protrudes from the flow path forming body 12 and is connected to the flow path forming body 12. The metal base plate 11 is supported by the distal end portion of the support member 803. The flow path forming body 12 is connected to an electrical ground. A leakage current flow 804 indicates the direction of leakage current flowing from the driver circuit board 22 to the metal base plate 11, the support member 803, and the flow path forming body 12 in this order. A leakage current flow 805 indicates the direction of leakage current flowing from the control circuit board 20 to the metal base plate 11, the support member 803, and the flow path forming body 12 in this order. Thereby, the leakage current of the control circuit board 20 and the driver circuit board 22 can be efficiently passed to the ground.

  FIG. 14A is a perspective view of an AC-side relay conductor 802 that includes an AC terminal block 760 and an AC relay bus bar 750. FIG. 14B is a perspective view of the AC terminal block 760. FIG. 14C is a perspective view of the AC relay bus bar 750.

  Since the AC terminal block 760 and the AC terminal block 761 have the same structure, the AC terminal block 760 will be representatively described. Further, since the AC relay bus bar 750 and the AC relay bus bar 751 have the same structure, the AC terminal block 750 will be representatively described.

  As shown in FIG. 14B, the AC terminal block 760 includes an AC bus bar 763 and a resin block 762 that are integrally formed. As shown in FIG. 14A, the AC bus bar 763 is mechanically connected to the AC relay bus bar 750 at the lower portion thereof by screws or the like.

  An AC connector 188 is attached to the upper portion 763a of the AC bus bar 763 and is mechanically connected. Thus, since both ends of the AC bus bar 763 are mechanically connected by screws or the like, it is possible to select an inexpensive material having no weldability.

  As shown in FIG. 14C, the relay bus bar 750 includes a relay bus bar 753 and an insulating member 752 that are integrally formed. As shown in FIG. 15 described later, one end of the relay bus bar 753 is welded to the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301c. Therefore, the relay bus bar 753 needs to use a material having weldability. Relay bus bar 753 and AC bus bar 763 are connected by a first fastening member 771 that passes through a through-hole 755 formed in relay bus bar 753.

  At this time, the through-hole 755 has an elliptical shape with a long diameter formed along the arrangement direction of the AC terminal block 760 and the AC relay bus bar 750. As a result, tolerance variations due to the assembly of the AC terminal block 760 and the AC relay bus bar 750 can be allowed. As a result, the tolerance variation of the mounting surface of the AC connector 188 of the motor can be kept to a minimum, and the stress generated on the welded portion can be reduced to a minimum.

  Further, in the AC relay bus bar 750, the relay bus bar 753 and the insulating member 752 are integrally formed. Further, the AC terminal blocks 760 and 761 are integrally formed with an AC bus bar 763 and a resin block 762.

  FIG. 15 shows the lid 8, the control circuit board 20, the metal base plate 11, the driver circuit board 22, and the AC terminal blocks 760 and 761 in order to explain the welded connections of the power semiconductor modules 300 a to 300 c and 301 a to 301 c. FIG.

  Relay bus bar 753 is connected to AC terminal 320B of power semiconductor module 301a by welding connection, and forms AC welding connection portions 750a and 751a. That is, since the relay bus bar 753 is connected by welding, it is necessary to select a material having weldability. On the other hand, as shown in FIG. 14A, the AC bus bar 763 is only mechanically connected to the relay bus bar 753. Therefore, AC bus bar 763 can select a material that does not have weldability.

  As a result, the AC bus bar 763 has a higher degree of freedom in material selection than the relay bus bar 753. Therefore, by selecting a cheaper material, the material cost can be suppressed. Further, by making the volume of the relay bus bar 753 smaller than the volume of the AC bus bar 763, the cost can be further reduced.

  Furthermore, it is necessary for the AC welding connection portions 750a and 751a to ensure reliability including strength against vibration and impact. Therefore, it is desirable that the relay bus bar 753 and the AC terminal 320B have the same thickness as much as possible. That is, the selection of the material and the thickness of the relay bus bar 753 is limited, but the AC bus bar 763 is not limited in the selection of the material and the thickness by welding connection, and an improvement in design flexibility can be expected.

  The joining portions of the capacitor terminal 503a, the DC positive terminal 315B, and the DC negative terminal 319B are welded to form a DC welding connection 780a.

  The joining portions of the capacitor terminal 503b, the DC positive terminal 315B, and the DC negative terminal 319B are welded to form a DC welding connection 780b.

  The joining portions of the capacitor terminal 503c, the DC positive terminal 315B, and the DC negative terminal 319B are welded to form a DC welding connection 780c.

  The joining portion of the capacitor terminal 503d, the DC positive terminal 315B, and the DC negative terminal 319B is welded to form a DC welding connection 780d.

  The combined portion of the capacitor terminal 503e, the DC positive terminal 315B, and the DC negative terminal 319B is welded to form a DC weld connection 780e.

  The joint portions of the capacitor terminal 503f, the DC positive terminal 315B, and the DC negative terminal 319B are welded to form a DC welding connection 780f.

  At this time, the capacitor module 500, the power semiconductor modules 300 a to 300 c, and the power semiconductor modules 301 a to 301 c forming the DC welding connection portions 780 a to 780 f are all attached to the flow path forming body 12. That is, the capacitor module 500, the power semiconductor modules 300a to 300c, and the power semiconductor modules 301a to 301c are fixed to an integrally formed base (flow path forming body 12). As a result, it is possible to keep the resonance point frequency at the time of vibration of the DC welding connection portions 780a to 780f high, so that the reliability of the welded portion can be improved.

  In addition, the mating portion of relay bus bar 753 and power semiconductor module 300a is welded to form AC welding connection portion 750a.

  The mating portion of relay bus bar 753 and power semiconductor module 300b is welded to form an AC welding connection portion 750b.

  The mating portion of relay bus bar 753 and power semiconductor module 300c is connected by welding to form AC welding connection portion 750c.

  The mating portion of relay bus bar 753 and power semiconductor module 301a is welded to form an AC welding connection portion 751a.

  The mating portion of relay bus bar 753 and power semiconductor module 301b is welded to form an AC welding connection portion 751b.

  The mating portion of relay bus bar 753 and power semiconductor module 301c is welded to form an AC welding connection portion 751c.

  At this time, the AC relay bus bars 750 and 751 forming the AC welding connection parts 750a to 750c and 751a to 751c are attached to the flow path forming body 12, and as described above, the power semiconductor modules 300a to 300c and the power semiconductor modules 301a to 301a. 301 c is attached to the flow path forming body 12. That is, the AC relay bus bars 750 and 751, the power semiconductor modules 300a to 300c, and the power semiconductor modules 301a to 301c are fixed to an integrally formed base (flow path forming body 12). As a result, the AC welding connection parts 750a to 750c and 751a to 751c can maintain the resonance point frequency during vibration similarly to the DC welding connection parts 780a to 780f, so that the reliability of the welding part can be improved. It becomes possible.

  Furthermore, the flow path forming body 12 includes a first flow path forming body 441 (see FIG. 3) for cooling the power semiconductor modules 300a to 300c and 301a to 301c. AC relay bus bars 750 and 751 are attached in the vicinity of power semiconductor modules 300a to 300c and power semiconductor modules 301a to 301c. That is, the flow path forming body 441 and the AC relay bus bars 750 and 751 are installed very close to each other. Thus, heat from AC connector 188 is transmitted from AC bus bar 763 to relay bus bar 753 in the direction of arrow 755 indicated by the dotted line, as shown in FIG. Further, the heat from the AC connector 188 is cooled by the flow path forming body 441 of the flow path forming body 12 via the insulating member 752.

  At this time, it is possible to actively dissipate heat from the AC connector 188 by forming the relay bus bar 753 thicker than the AC terminal 320B, so that the power semiconductor modules 300a to 300c and The improvement of durability including the heat resistance of 301a-301c can be expected. However, if the thickness of the bus bars to be welded is significantly different, there is a concern about deterioration in durability including strength due to vibration and impact after welding and deterioration of weldability. The difference in the thickness of each bus bar is limited to 30% or less. However, this is not the case when the above concerns are resolved.

8 Lid 11 Base plates 11a to 11b Through hole 12 Flow path forming bodies 12a to 12d Side wall 13 Inlet pipe 14 Outlet pipe 19a First flow path part 19b Second flow path part 19c Third flow path part 19d Fourth flow path part 19e 5th flow path part 19f 6th flow path part 19g 7th flow path part 19h 8th flow path part 19i 9th flow path part 20 Control circuit board 21 Connector 22 Driver circuit boards 22a-22f Through-hole 23a Connection part 23b Connection part 24 Transformer 138 DC connector 156, 166 Diode 200 Power converter 202 First opening 203 Second opening 204a Third opening 204b Fourth opening 205 Fifth opening 300a-300c, 301a-301c Power semiconductor module 302 Module primary sealing body 304 Module case 304A Thin portion 304B Flange 305 Fin 306 Insertion slot 30 A First heat dissipation surface 307B Second heat dissipation surface 309 Screw 315 Conductor plate 315A DC positive electrode wiring 315B DC positive electrode terminal 315C Auxiliary module side DC positive electrode connection terminal 315D Element side DC positive electrode connection terminal 318, 319, 320 Conductor plate 319A DC negative electrode wiring 319B DC negative terminal 319C Auxiliary module side DC negative connection terminal 319D Element side DC negative connection terminal 320A AC wiring 320B AC terminal 320C Auxiliary module side AC connection terminal 320D Element side AC connection terminal 322 Element fixing part 324U, 324L Signal wiring 325L, 325U Signal Terminals 326L, 326U Auxiliary module side signal connection terminals 327L, 327U Element side signal connection terminals 328, 330 IGBT
328A, 330A Control electrode 329 Intermediate electrode 333 Insulating member 348 First sealing resin 350 Auxiliary power module 351 Second sealing resin 360 Power semiconductor module height 370 Connection portion 371 Bonding wire 372 Tie bars 400a to 400c Opening portion 402a ˜402c Opening portion 404 Opening portion 405 Storage space 406a to 406f Protruding portion 409 Seal member 417 Flow direction 420 Lower cover 441 First flow path forming body 442 Second flow path forming body 444 Third flow path forming body 500 Capacitor module 501 Lamination Conductor plate 502 Capacitor cases 503a to 503f Capacitor terminal 505 Negative electrode plate 507 Positive electrode plate 508 Negative side power source terminal 509 Positive side power source terminal 510 Negative side power line 511 Storage portion 512 Positive side power line 514 Capacitor cell 5 5a, 515b Capacitor cells 516, 517 for noise filters Capacitor terminals 520a to 520h for auxiliary machines Hole 530 Relay conductor part 540 Capacitor module height 550 Insulation sheet 551 Filler 600 Auxiliary mold body 608 Wiring insulation part 750 AC relay bus bar 751 AC Relay bus bar 750a to 750c AC welding connection 751a to 751c AC welding connection 752 Insulating member 753 Relay bus bar 755 Through hole 760, 761 AC terminal block 762 Resin block 763 AC bus bar

Claims (4)

A power semiconductor module that converts direct current to alternating current;
A housing forming a storage space for storing the power semiconductor module;
An AC relay busbar connected by fusion connection with an AC terminal of the power semiconductor module;
An AC terminal block connected to the AC terminal of the motor,
The AC relay bus bar is supported by the housing via an insulating member,
The AC terminal block is connected to the AC relay busbar and supported by the housing,
The AC terminal block has an AC bus bar connected by mechanical connection with the AC relay bus bar, and a resin block that supports the AC bus bar,
The power conversion device in which an attachment surface of the casing that supports the AC relay bus bar is orthogonal to an extending direction of the AC bus bar. The power conversion device according to claim 1,
The insulating member is a power conversion device that integrally holds a plurality of the AC relay bus bars. The power conversion device according to claim 1 or 2,
The AC relay bus bar forms a first through hole,
The first through hole has an elliptical shape in which a long diameter is formed along an arrangement direction of the AC terminal block and the AC relay bus bar,
The AC terminal block is a power converter connected to the AC relay busbar by a first fastening member passing through the first through hole. The power conversion device according to any one of claims 1 to 3,
The housing has a flow path forming body through which a cooling refrigerant flows,
The power semiconductor device and the AC relay bus bar are power converters fixed to the flow path forming body.

Images