Classifications

• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
  • H05K7/00—Constructional details common to different types of electric apparatus
  • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
  • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
  • H05K7/20927—Liquid coolant without phase change
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
  • H05K7/00—Constructional details common to different types of electric apparatus
  • H05K7/14—Mounting supporting structure in casing or on frame or rack
  • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
  • H05K7/1427—Housings
  • H05K7/1432—Housings specially adapted for power drive units or power converters
  • H05K7/14329—Housings specially adapted for power drive units or power converters specially adapted for the configuration of power bus bars

Definitions

• the subject of the invention is a voltage conversion system intended to equip a motor vehicle.
• the invention also relates to a method of manufacturing such a voltage conversion system.
• Voltage conversion systems comprising a voltage converter, a housing comprising a cooling device, the voltage converter being positioned inside the housing so as to be in thermal contact with the cooling device, and a connector electric.
• the electrical connector includes a first and a second busbar and is adapted to electrically connect the voltage converter to at least one electrical network via the first and the second busbar.
• the object of the invention is to at least partially overcome the aforementioned problem.
• a voltage conversion system comprising:
• a housing comprising a cooling device, the voltage converter being positioned inside the housing so as to be in thermal contact with the cooling device, and
• an electrical connector comprising a first and a second busbar, the electrical connector being designed to electrically connect the voltage converter to at least one electrical network via the first and the second busbar.
• the system is further characterized in that the first busbar is in thermal contact with the cooling device through the exterior of the housing.
• a bus bar is a low impedance conductor, for example a metal bar, for example made of copper. Thanks to the thermal contact of the first bus bar with the cooling device via the exterior of the casing, it is possible to cool this first bus bar and thus to avoid excessive heating of the electrical connector.
• a voltage conversion system according to the invention may further comprise one or more of the following optional characteristics, taken in isolation or else according to any technically possible combination.
• the electrical connector is fixed to the housing.
• the voltage converter is a DC-DC voltage converter also called DC/DC converter.
• the voltage converter is a DC/AC voltage converter also called a DC/AC converter.
• the electrical connector further comprises a first and a second connection terminal, the first busbar and the second busbar being adapted to be mechanically and electrically connected to said at least one electrical network by means of the first connection terminal and the second connection terminal.
• the first connection terminal is a metal stud, for example steel.
• the second connection terminal is a metal stud, for example steel.
• the second bus bar is in thermal contact with the cooling device via the exterior of the casing.
• the first busbar and/or the second busbar is formed in one piece, i.e. in continuity of material.
• part of the first busbar and/or part of the second busbar is located inside the casing.
• the electrical connector comprises an overmolding of electrically insulating material, for example plastic, the overmolding at least partially overmolding the first and the second bus bar.
• the overmoulding holding the first busbar and the second busbar together.
• the housing further comprises a support plate capable of delimiting a first volume of the housing in which a cooling fluid is intended to circulate to cool the voltage converter with respect to a second volume of the housing in which is positioned the voltage converter.
• the housing comprises a cooling fluid inlet, a cooling fluid outlet and the first volume comprises at least one cooling channel connecting the cooling fluid inlet to the cooling fluid outlet.
• the case comprises a bottom and a peripheral side wall surrounding the bottom and the cooling channel is delimited at least in part by the support plate and/or the bottom and/or the peripheral side wall and/or by at least one wall extending between the bottom and the support plate.
• the peripheral side wall comprises a first face facing the outside of the case, the peripheral side wall extending between the bottom and the support plate, a part of the support plate extending substantially perpendicular to the first face of the peripheral side wall, the part comprising a through hole arranged to receive the electrical connector, the support plate comprising a second face on which the voltage converter is positioned and a second face opposite the second face of the support plate , the electrical connector being fixed to the first face of the support plate.
• the peripheral side wall, the support plate and said at least one wall extending between the bottom and the support plate are made in continuity of material, for example by a casting process.
• the first bus bar is in thermal contact with the cooling device via the exterior of the casing via a thermally conductive connecting element, for example by a thermally conductive paste or by a thermal pad (of English "Gad Pad")
• the cooling device comprises a sole having a first face intended to receive heat to be dissipated emitted by the voltage converter, and at least one fin extending on a second face of the sole opposite to the first face, the first face of the sole being turned towards the inside of the casing, the first bus bar being in thermal contact with the second face of the sole.
• the electrical connector further comprises a first auxiliary connection terminal, the first busbar and the second busbar being adapted to be mechanically and electrically connected to said at least one electrical network by means of the first terminal respectively auxiliary connection and the second connection terminal.
• the electrical connector further comprises a first auxiliary connection terminal and a second auxiliary connection terminal, the first busbar and the second busbar being adapted to be mechanically and electrically connected to said at least one electrical network by the intermediary respectively of the first auxiliary connection terminal and of the second auxiliary connection terminal.
• the first auxiliary connection terminal is a metal stud, for example steel.
• the second auxiliary connection terminal is a metal stud, for example steel.
• an electrical connector comprising a first and a second busbar, the electrical connector being designed to electrically connect the voltage converter to at least one electrical network via the first and the second busbar,
• the mounting method according to the invention may further comprise the following optional feature, according to which the mounting method further comprises fixing the electrical connector to the housing.
• FIG. 1 is a top view of a voltage conversion system according to one embodiment of the invention.
• FIG. 2 is an exploded three-dimensional view of the voltage conversion system shown in Figure 1.
• FIG. 3 is an exploded three-dimensional view of the top of the case of the voltage conversion system of Figure 1.
• FIG. 4 is a view of the bottom of the case of the voltage conversion system of Figure 1.
• FIG. 5 represents the electrical connector without overmoulding of the voltage conversion system of figure 1.
• FIG. 6 represents, in the form of a flowchart, the different stages of a method of manufacturing the voltage conversion system of figure 1.
• FIG 1 shows a top view of a voltage conversion system 1000 in one embodiment of the invention.
• the voltage conversion system 1000 includes a voltage converter 100 designed to convert a first voltage VI to a second voltage V2, a housing 200 including a cooling device for cooling the voltage converter 100 and a 300 electrical connector.
• the electrical connector 300 is also attached to the housing 200.
• the electrical connector 300 is a separate part of the housing 200 before its assembly on the housing 200.
• the voltage converter 100 is in the example described here a DC/DC voltage converter called DC/DC voltage converter.
• This voltage converter is intended to be embedded in a vehicle in order to perform a voltage conversion between a first electrical network and a second electrical network of the vehicle.
• the first electrical network is a low voltage network delivering a first electrical voltage V 1 less than 30V, for example approximately 24 or 12V
• the second electrical network is a high voltage network which delivers a second electrical voltage V2 greater than 30V , for example 48V.
• the voltage converter 100 comprises an electronic card 110 comprising a plurality of voltage choppers (not shown in FIG. 2) in parallel.
• Each of the voltage choppers comprises an inductance and two transistors operating as electronic switches.
• MOSFET transistors from the English “Metal Oxide Semiconductor Field Effect Transistor”.
• these transistors can also be IGBT transistors (standing for “Insulated Gate Bipolar Transistor”) or even FET power transistors (standing for “Field Effect Transistor”) made of gallium nitride (GaN).
• the housing 200 comprises a bottom 210, a peripheral side wall 220 surrounding the bottom 210, a support plate 230 and a cooling device intended to cool the voltage converter 100.
• the peripheral side wall 220 extends between the bottom 210 and said support plate 230 and comprises a first face facing the outside of the box 200.
• the bottom 210 is in the form of a cover positioned on a bearing surface of the peripheral side wall 220 and fixed, for example by friction-mixing, to the peripheral side surface 220.
• the cover can be screwed onto a bearing surface of the peripheral side wall 220 by inserting a seal between the cover and the peripheral side wall 220.
• the support plate 230 delimits a first volume PV 1 of the casing 200 in which a cooling fluid, for example water, is intended to circulate to cool the voltage converter 100 and a second volume PV2 of the casing 200 in which is mounted the voltage converter 100.
• the support plate 230 thus comprises a first face facing the first volume PV 1 and a second face facing the second volume PV2, the second face being opposite the first face.
• the voltage converter 100 is positioned and fixed on the second face, for example by screws.
• the voltage converter 100 is fixed on the second face by riveting or else by gluing.
• the housing 200 further comprises a cooling fluid inlet 240 and a cooling fluid outlet 250 while the first volume consists of a cooling channel connecting the cooling fluid inlet 240 to the cooling fluid outlet. 250.
• the cooling channel is delimited by the first face of the support plate 230, by the bottom 210, by the peripheral side wall 220 and by walls 260 extending between the bottom 210 and the plate. -bracket 230.
• the cooling channel, the cooling fluid inlet, the cooling fluid outlet and the support plate constitute a cooling device for the voltage converter 100.
• a part 235 of the support plate 230 extends substantially perpendicular to the first face of the peripheral side wall 220, this part 235 comprising a through hole 236 arranged to receive the electrical connector 300 so that this electrical connector 300 is fixed to the first face of the support plate 230.
• the peripheral side wall 220, the support plate 230 and the walls 260 are made in continuity of material, for example of metal such as aluminum, for example by a casting process.
• the peripheral side wall 220, the support plate 230 and the walls 260 constitute a single piece of metal, for example aluminum, made for example by a casting process.
• the peripheral side wall 220, the support plate 230 and the walls 260 can be parts made separately before being assembled.
• the electrical connector 300 includes a first positive bus bar 310, a second positive bus bar 320 and a negative bus bar 330, the negative bus bar 330 being intended to be connected to an electrical ground.
• the first positive bus bar 310 is metallic, for example copper.
• the second positive bus bar 320 is metallic, for example copper.
• the negative bus bar 330 is also metallic, for example copper.
• the first positive busbar 310, the second positive busbar 320 and the negative busbar 330 are also formed in one piece, ie in continuity of material.
• the electrical connector 300 is designed to electrically connect the voltage converter 100 to the first electrical network via the first positive busbar 310 and the negative busbar 330 and to the second electrical network via the second busbar positive 320 and negative bus bar 330.
• the first positive bus bar 310, the second positive bus bar 320 and the negative bus bar 330 are rigid electrical conductors designed to withstand electrical current densities of at least 10 A/mm 2 .
• first positive busbar 310 and the negative busbar 330 present between them the first electric voltage V1 and the second positive busbar 320 and the negative busbar 330 present between them the second electric voltage V2 when the voltage converter 100 converts the first electric voltage VI into the second electric voltage V2.
• a first positive connection terminal is fixed on a planar portion of the first positive bus bar 310
• a second positive connection terminal is fixed on a planar portion of the second positive bus bar 320
• a negative connection is attached to a flat portion of the negative bus bar 330.
• the first positive connection terminal, the second positive connection terminal and the negative connection terminal are respectively, in the example described here, studs 312, 322, 332.
• the studs 312, 322, 332 are threaded and made of metal, for example steel.
• the first positive connection terminal and the negative connection terminal make it possible to mechanically attach the busbars 310, 330 to electrical power cables in order to electrically connect these busbars 310, 330 to the first electrical network.
• the second positive connection terminal and the negative connection terminal make it possible to mechanically attach the busbars 320, 330 to electrical power cables in order to electrically connect these busbars 320, 330 to the second electrical network.
• the attachment of an electric cable to one of these busbars is carried out for example by inserting the threaded stud of the busbar into the eye of a terminal of the electric cable then by screwing a nut on the threaded stud so pressing the terminal against the bus bar in order to make the electrical connection between the bus bar and the terminal.
• a first auxiliary positive connection terminal is attached to a planar portion of the first positive bus bar 310 and an auxiliary negative connection terminal 334 is attached to a planar portion of the negative bus bar 330.
• the first auxiliary positive connection terminal and the auxiliary negative connection terminal are respectively, in the example described here, studs 314, 334.
• the studs 314, 334 are made of metal, for example steel.
• the first auxiliary positive connection terminal and the auxiliary negative connection terminal make it possible to mechanically attach the bus bars 310, 330 to electrical power cables in order to electrically connect these bus bars 310, 330 to the first electrical network.
• the use of two different connection terminals makes it possible to mechanically and electrically fix the positive bus bar to the first electrical network by means of two different electrical supply cables.
• the second positive connection terminal and the auxiliary negative connection terminal make it possible to mechanically attach the busbars 320, 330 to electrical power cables in order to electrically connect these busbars 320, 330 to the second electrical network.
• the electrical connector 300 further includes a magnetic core 340 surrounding the first positive bus bar 310, the second positive bus bar 320 and the negative bus bar 330.
• the first positive bus bar 310, the second positive bus bar 320 and the negative bus bar 330 are at least partly overmoulded with an insulating material 350 (not visible in FIG. 5 but visible in FIG. 2), for example by a insulating plastic material.
• the magnetic core 340 is mounted around the first positive busbar 310, the second positive busbar 320 and the negative busbar 330 after molding these three busbars 310, 320, 330.
• the first end of the first positive busbar 310 has a general T shape.
• the first positive connection terminal and the first auxiliary positive connection terminal are each fixed to a different end of the crossbar of this T.
• the first end of the negative bus bar 330 has the general shape of a T.
• the negative connection terminal and the auxiliary negative connection terminal are each located at a different end of the bar transverse of this T.
• first end of the first positive bus bar 310 could have a general Y shape.
• the first positive connection terminal and the first auxiliary positive connection terminal would each be attached to one end of a different leg of this Y.
• the first end of the negative bus bar 330 could have a general Y shape.
• the negative connection terminal and the auxiliary negative connection terminal would each be located at one end of a different leg of this Y.
• the electrical connector 300 is fixed, for example by screws, to the outside of the housing 200 on the first face of the support plate 230.
• the electrical connector 300 is fixed on the first face of the support plate 230 at the level of a stud 270 located at the level of its part 235 and at the level of at least one fixing stud 271 located on the first face of the support plate 230.
• a second end of the first positive busbar 310, a second end of the second positive busbar 320 and a second end of the negative busbar 330 are inserted into the hole. opening 236 so that these ends are located inside the housing 200 and more precisely in the second volume PV2 of housing 200 and so that these ends can be physically connected to voltage converter 100.
• a gasket surrounding through-hole 236 may be inserted between electrical connector 300 and housing 200 when attaching electrical connector 300 to housing 200.
• first positive bus bar 310 and negative bus bar 330 are brought into thermal contact with housing cooler 200 via the exterior of this case 200.
• the first positive bus bar 310 and the negative bus bar 330 can be cooled which limits their heating as well as heating of the electrical connector 300 and cables connected to the terminals of this electrical connector 300.
• the first positive bus bar 310 is in thermal contact with the exterior of the housing 200 via at least one thermal pad placed between an exterior surface of the housing 200 and a surface of the first bus. positive omnibus 310.
• thermal pads 410, 420 and 430 are placed between the housing 200 and the first positive bus bar 310
• negative bus bar 330 is in thermal contact with the exterior of housing 200 through at least one thermal pad positioned between an exterior surface of housing 200 and a surface of negative bus bar 330.
• the first positive bus bar 310 and/or the negative bus bar 330 are in thermal contact with the exterior of the housing 200 via a thermally conductive paste placed between them and an exterior surface of the housing 200.
• the first positive bus bar 310 is in thermal contact with the bottom 210 and with the peripheral side wall 220 of the housing 200. In this way, the circulation of the cooling fluid in the cooling channel and, by Consequently, in contact with the bottom 210 and with the peripheral side wall 220 makes it possible to cool the first positive bus bar 310.
• the negative bus bar 330 is in thermal contact with the first surface of the support plate 230. In this way, the circulation of the cooling fluid in the cooling channel and, therefore, in contact with the support plate 230 makes it possible to cool the negative bus bar 330.
• the cooling device may comprise a radiator comprising a soleplate and at least one fin (not shown in the figures).
• the sole of the radiator comprises a first face intended to receive the heat to be dissipated emitted by the voltage converter 100, and a second face opposite the first face. On the second face, extends said at least one fin.
• the first face of the sole is turned towards the interior of the casing and the second face of the sole is turned toward the exterior of the casing.
• the bottom 210 of the box 220 can constitute such a sole.
• the first positive bus bar 310 is in thermal contact with the second face of the sole, ie with the outer part of the bottom 210, via said at least one thermal pad and via the side walls 220 of the box 200.
• a voltage converter 100 is obtained.
• a box 200 comprising a cooling device is obtained.
• the voltage converter 100 is positioned in the housing 200 so that the voltage converter 100 is in thermal contact with the cooling device,
• an electrical connector 300 comprising a first 310 and a second 330 bus bar, said electrical connector being designed to electrically connect said voltage converter 100 to at least one electrical network via said first and of said second busbar is obtained,
• the electrical connector 300 is attached to the box 200,
• a step E2600 the first busbar 310 is brought into thermal contact with the cooling device via the exterior of the housing 200.
• the second busbar 330 is placed in thermal contact with the cooling device through the exterior of the housing 200.
• the voltage converter could be a DC/AC voltage converter and the electrical connector could only be able to electrically connect the voltage converter 100 to the second electrical network.
• the electrical connector would comprise only the second positive bus bar and the negative bus bar, said second positive bus bar being in thermal contact for its cooling with the outside of the case of the conversion system electric.
• voltage conversion system 100 could have no cooling channel and only include a heatsink.
• the bottom 210 and the support wall 230 constitute one and the same piece.

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• Engineering & Computer Science (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Dc-Dc Converters (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (1)

Family

ID=76375281

Family Applications (1)

Country Status (4)

Citations (6)

• 2021
  • 2021-05-10 FR FR2104951A patent/FR3122802A1/fr active Pending
• 2022
  • 2022-05-10 CN CN202280048430.3A patent/CN117616885A/zh active Pending
  • 2022-05-10 WO PCT/EP2022/062567 patent/WO2022238366A1/fr active Application Filing
  • 2022-05-10 EP EP22728495.7A patent/EP4338560A1/fr active Pending

Patent Citations (6)

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