WO2024095903A1 - 電力変換装置、モータモジュール、および電力変換装置の製造方法 - Google Patents

電力変換装置、モータモジュール、および電力変換装置の製造方法 Download PDF

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Publication number
WO2024095903A1
WO2024095903A1 PCT/JP2023/038815 JP2023038815W WO2024095903A1 WO 2024095903 A1 WO2024095903 A1 WO 2024095903A1 JP 2023038815 W JP2023038815 W JP 2023038815W WO 2024095903 A1 WO2024095903 A1 WO 2024095903A1
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WIPO (PCT)
Prior art keywords
core
shield
conversion device
power conversion
shield core
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Ceased
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PCT/JP2023/038815
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English (en)
French (fr)
Japanese (ja)
Inventor
智史 町野
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Nidec Corp
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Nidec Corp
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Publication date
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Priority to CN202380076063.2A priority Critical patent/CN120153567A/zh
Priority to JP2024554463A priority patent/JPWO2024095903A1/ja
Publication of WO2024095903A1 publication Critical patent/WO2024095903A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/42—Conversion of DC power input into AC power output without possibility of reversal
    • H02M7/44—Conversion of DC power input into AC power output without possibility of reversal by static converters
    • H02M7/48—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode

Definitions

  • the present invention relates to a power conversion device, a motor module, and a method for manufacturing a power conversion device.
  • a power conversion device that supplies power to a motor, as described in Patent Document 1, includes a bus bar and a sensor (Hall IC) that detects the value of the current flowing through the bus bar inside a shield core that collects the magnetic field generated by the current flowing through the bus bar.
  • a sensor Hap IC
  • the dimensional tolerance of the shield core is likely to be large. Therefore, when the shield core is fixed to a resin support part or the like by press-fitting, depending on the dimensional tolerance of the shield core, it may be difficult to easily press the shield core into the support part, etc., and there is a risk that the manufacturing labor and manufacturing costs of the power conversion device will increase.
  • one aspect of the present invention aims to provide a power conversion device and a motor module that can easily fix a shield core to a support part.
  • Another aspect of the present invention aims to provide a method for manufacturing a power conversion device that can easily fix a shield core to a support part.
  • One embodiment of the power conversion device of the present invention includes a bus bar extending in a first direction, a sensor that detects a magnetic field generated by a current flowing through the bus bar, a magnetic shield core that surrounds the bus bar and the sensor from both sides in a second direction perpendicular to the first direction and from at least one side in a third direction perpendicular to the first direction and the second direction, a core sealing portion that seals at least a portion of the shield core with resin, and a support portion.
  • the shield core is fixed to the support portion via the core sealing portion.
  • One embodiment of the motor module of the present invention includes the above-mentioned power conversion device and a motor driven by the above-mentioned power conversion device.
  • One aspect of the method for manufacturing a power conversion device of the present invention is a method for manufacturing a power conversion device that includes a magnetic shield core, a resin core sealing part, and a support part, and includes a positioning step for determining the position of the shield core relative to the support part within a mold, and a molding step for sealing at least a portion of the shield core with resin by injection molding using the support part and the shield core as insert members, and molding the core sealing part that is fixed to the support part.
  • the shield core in a power conversion device and a motor module, can be easily fixed to the support part. Also, according to one aspect of the present invention, in a method for manufacturing a power conversion device, the shield core can be easily fixed to the support part.
  • FIG. 1 is a schematic diagram showing a motor module according to an embodiment.
  • FIG. 2 is a perspective view showing a part of the power conversion device of the embodiment.
  • FIG. 3A is a top view showing a portion of a power conversion device according to one embodiment.
  • FIG. 3B is a cross-sectional view showing the power conversion device of the embodiment.
  • FIG. 4 is a top view showing the support portion and shield core of one embodiment.
  • FIG. 5A is a flowchart showing a method for manufacturing a power conversion device according to one embodiment.
  • FIG. 5B is a first cross-sectional view illustrating a method for manufacturing the power converter according to the embodiment.
  • FIG. 5C is a second cross-sectional view showing the method for manufacturing the power converter according to the embodiment.
  • FIG. 5A is a flowchart showing a method for manufacturing a power conversion device according to one embodiment.
  • FIG. 5B is a first cross-sectional view illustrating a method for manufacturing the power converter according to the embodiment
  • FIG. 5D is a third cross-sectional view illustrating the method for manufacturing the power converter according to the embodiment.
  • FIG. 6A is a top view illustrating a portion of a power conversion device according to a first modification of the embodiment.
  • FIG. 6B is a cross-sectional view illustrating a power conversion device according to the first modification of the embodiment.
  • FIG. 7A is a top view illustrating a portion of a power conversion device according to a second modification of the embodiment.
  • FIG. 7B is a cross-sectional view illustrating a power conversion device according to a second modification of the embodiment.
  • FIG. 8A is a top view illustrating a portion of a power conversion device according to a third modification of the embodiment.
  • FIG. 8B is a cross-sectional view illustrating a power conversion device according to a third modification of the embodiment.
  • FIG. 9A is a top view illustrating a portion of a power conversion device according to a fourth modified example of the embodiment.
  • FIG. 9B is a cross-sectional view illustrating a power conversion device according to a fourth modified example of the embodiment.
  • the first direction D1 is shown in each figure as appropriate.
  • the first direction D1 is the direction in which the busbars in the embodiment described below extend.
  • the first direction D1 is the front-to-rear direction of the power conversion device.
  • the side toward which the arrow of the first direction D1 points (+D1 side) is referred to as "one side of the first direction D1" or "rear side.”
  • the side opposite to the side toward which the arrow of the first direction D1 points (-D1 side) is referred to as "the other side of the first direction D1" or "front side.”
  • the second direction D2 is shown in each figure as appropriate.
  • the second direction D2 is the direction in which multiple bus bars are arranged side by side, and is a direction perpendicular to the first direction D1.
  • the second direction D2 is the left-right direction of the power conversion device.
  • the side toward which the arrow of the second direction D2 points (+D2 side) is referred to as "one side of the second direction D2" or "left side.”
  • the side opposite to the side toward which the arrow of the second direction D2 points (-D2 side) is referred to as "the other side of the second direction D2" or "right side.”
  • the third direction D3 is shown in each figure as appropriate.
  • the third direction D3 is a direction perpendicular to the first direction D1 and the second direction D2.
  • the third direction D3 is the up-down direction of the power conversion device.
  • the side toward which the arrow of the third direction D3 points (the +D3 side) is referred to as "one side of the third direction D3" or "lower side.”
  • the side opposite to the side toward which the arrow of the third direction D3 points (the -D2 side) is referred to as "the other side of the third direction D3" or "upper side.”
  • FIG. 1 is a schematic diagram showing a motor module 1 of the present embodiment.
  • the motor module 1 is a drive device mounted on a vehicle to rotate the axle of the vehicle.
  • the vehicle on which the motor module 1 is mounted is a vehicle that uses a motor as a power source, such as a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or an electric vehicle (EV).
  • the motor module 1 includes a motor 2 and a power conversion device 10.
  • Motor 2 rotates the axle of the vehicle (not shown).
  • motor 2 is a three-phase motor.
  • the three phases are U-phase, V-phase, and W-phase.
  • Motor 2 has U-phase coil, V-phase coil, and W-phase coil (not shown).
  • the power conversion device 10 generates a current to be supplied to the motor 2, and supplies a current to each of the U-phase coil, the V-phase coil, and the W-phase coil of the motor 2.
  • the power conversion device 10 is connected to the motor 2, the control unit 3, and the external power source 4.
  • the control unit 3 controls the operation of the vehicle.
  • the control unit 3 transmits a control signal including instructions related to the operation of the motor 2 to the power conversion device 10.
  • the external power source 4 supplies a direct current to the power conversion device 10.
  • the external power source 4 is a battery.
  • the power conversion device 10 Based on a control signal transmitted from the control unit 3, the power conversion device 10 generates a current of a predetermined waveform from the DC current supplied by the external power source 4, and supplies the current to the motor 2. More specifically, the power conversion device 10 generates phase currents (U-phase current, V-phase current, and W-phase current) to be supplied to the U-phase coil, V-phase coil, and W-phase coil of the motor 2, respectively.
  • the power conversion device 10 is an inverter that converts DC current to AC current.
  • the power conversion device 10 and the motor 2 are connected by three connection lines 6. Each of the connection lines 6 is connected to one of the U-phase coil, V-phase coil, and W-phase coil of the motor 2, and current is supplied to each of the U-phase coil, V-phase coil, and W-phase coil via each connection line 6.
  • the power conversion device 10 includes a case 11, a support portion 12, an IGBT (Insulated Gate Bipolar Transistor) module 16, a circuit board 20, a sensor 25, a bus bar 30, a shield core 40, and a core sealing portion 50.
  • IGBT Insulated Gate Bipolar Transistor
  • the case 11 houses the support portion 12, the IGBT module 16, the circuit board 20, the sensor 25, the bus bar 30, the shield core 40, and the core sealing portion 50 inside.
  • the case 11 is a hollow box.
  • the case 11 is made of metal.
  • the case 11 is grounded.
  • the case 11 has a bottom wall portion 11a.
  • the bottom wall portion 11a is a plate-like member that extends in a direction perpendicular to the third direction D3.
  • the plate surface of the bottom wall portion 11a faces the third direction D3.
  • the IGBT module 16 generates phase currents to be supplied to the U-phase coil, V-phase coil, and W-phase coil of the motor 2 from the direct current supplied by the external power supply 4.
  • the IGBT module 16 has a plurality of electronic elements (not shown), such as a plurality of insulated gate bipolar transistors (IGBTs). Although not shown, the IGBT module 16 is connected to the control unit 3 and external power supply 4 shown in FIG. 1. The IGBT module 16 is fixed to the bottom wall portion 11a.
  • the circuit board 20 is a printed circuit board that extends in a direction perpendicular to the third direction D3. When viewed in the third direction D3, the circuit board 20 is substantially rectangular. Although not shown, the circuit board 20 is connected to the control unit 3 and external power supply 4 shown in FIG. 1. Although not shown, a plurality of pins of the IGBT module 16 are connected to the circuit board 20. In this way, the circuit board 20 is electrically connected to the IGBT module 16. A plurality of electronic elements and sensors 25 (not shown) are mounted on the circuit board 20. As shown in FIG. 2, the circuit board 20 is provided with a hole 20b. The circuit board 20 has a board protrusion 20d.
  • the holes 20b are holes that penetrate the circuit board 20 in the third direction D3. In this embodiment, ten holes 20b are provided. When the screws 90 are passed through each hole 20b in the third direction D3 and tightened into screw holes (not shown) of the IGBT module 16, the circuit board 20 is fixed to the IGBT module 16.
  • the board protrusion 20d is a portion of the circuit board 20 that protrudes toward the front (-D1 side). When viewed in the third direction D3, the board protrusion 20d is substantially rectangular. In this embodiment, three board protrusions 20d are provided. Each board protrusion 20d is disposed at a distance from the others along the second direction D2.
  • the support portion 12 is a substantially rectangular parallelepiped extending in the third direction D3. As shown in FIG. 3A, when viewed in the third direction D3, the support portion 12 is a substantially rectangular shape with its long sides extending in the second direction D2. In this embodiment, the support portion 12 is made of metal. In this embodiment, the support portion 12 is fixed to the surface facing the upper side of the bottom wall portion 11a by a screw or the like (not shown). As a result, the support portion 12 is grounded via the case 11. The support portion 12 may be connected to the bottom wall portion 11a. In this case, the support portion 12 is a part of the case 11. As shown in FIG. 3B, the support portion 12 is provided with a storage portion 12c.
  • the support portion 12 has an upper surface 12a, a support surface 12d, and a plurality of positioning portions 13.
  • the upper surface 12a is the surface of the outer surface of the support portion 12 facing upward, i.e., the other side (-D3 side) of the third direction D3.
  • the accommodation portion 12c is a hole recessed downward from the upper surface 12a, i.e., toward one side (+D3 side) in the third direction D3. As shown in FIG. 4, the accommodation portion 12c is generally rectangular with its long side extending in the second direction D2. As shown in FIG. 3B, the left end (+D2 side) of the accommodation portion 12c is located to the left of the leftmost board protrusion 20d. The right end (-D2 side) of the accommodation portion 12c is located to the right of the rightmost board protrusion 20d.
  • the support surface 12d is the inner surface of the storage section 12c that faces the other side (-D3 side) of the third direction D3.
  • the support surface 12d is the bottom surface of the storage section 12c.
  • the multiple positioning portions 13 are rectangular parallelepipeds that protrude upward from the support surface 12d. As shown in FIG. 4, when viewed in the third direction D3, each positioning portion 13 is rectangular with its long side extending in the first direction D1. In this embodiment, six positioning portions 13 are provided. The positioning portions 13 are arranged at intervals from one another along the second direction D2.
  • the positioning portions 13 are arranged in three sets in the second direction D2, with two adjacent positioning portions 13 in each set.
  • the left side of the right positioning portion 13, i.e., the surface facing one side (+D2 side) of the second direction D2 is the positioning surface 13a.
  • the right side of the left positioning portion 13, i.e., the surface facing the other side of the second direction D2 is the positioning surface 13b.
  • the positioning surface 13a and the positioning surface 13b face each other in the second direction D2.
  • the positioning surface 13a and the positioning surface 13b facing each other in the second direction D2 are referred to as a "pair of positioning surfaces 13a, 13b.”
  • the support portion 12 has three pairs of positioning surfaces 13a, 13b.
  • a gap is provided between each of the positioning portions 13 and the inner surface of the storage portion 12c. That is, in the first direction D1, a gap is provided between each of the pair of positioning surfaces 13a, 13b and the inner surface of the storage portion 12c.
  • the busbar 30 is a path through which the current generated in the IGBT module 16 flows. As shown in FIG. 2, the busbar 30 is in the shape of a plate extending in the first direction D1. The busbar 30 is made of metal. A portion of the busbar 30 is disposed below the circuit board 20 (on the +D3 side). Although not shown in the figure, one end of the busbar 30 is fixed to an electrode (not shown) of the IGBT module 16 by a screw (not shown). This allows a phase current to flow through the busbar 30. The other end of the busbar 30 is located forward (on the -D1 side) of the circuit board 20. Although not shown in the figure, the other end of the busbar 30 is electrically connected to the connection line 6 (see FIG. 1).
  • the power conversion device 10 includes a plurality of busbars 30.
  • Each busbar 30 carries one of the U-phase current, the V-phase current, and the W-phase current.
  • the bus bars 30 are arranged side by side in the second direction D2.
  • each of the board protrusions 20d of the circuit board 20 overlaps with each of the bus bars 30.
  • the sensor 25 is a magnetic detection sensor that detects a magnetic field generated by the current flowing through the busbar 30.
  • the sensor 25 is a Hall IC.
  • the sensor 25 converts the magnetic field into a voltage and outputs it.
  • the magnitude of the voltage output from the sensor 25 correlates with the magnitude of the current flowing through the busbar 30. This allows the sensor 25 to detect the magnitude of the current flowing through the busbar 30.
  • three sensors 25 are provided. That is, the power conversion device 10 is equipped with a plurality of sensors 25. Each sensor 25 is mounted on a different board protrusion 20d. As shown in FIG. 3B, the sensors 25 are arranged side by side in the second direction D2.
  • Each sensor 25 is arranged on the upper side (-D3 side) of the busbar 30. When viewed in the third direction D3, each sensor 25 overlaps with approximately the center of the busbar 30 in the second direction D2. Each sensor 25 detects the current values of the U-phase current, V-phase current, and W-phase current flowing through each busbar 30.
  • the output voltage of each sensor 25 is transmitted to a computing element (not shown) mounted on the circuit board 20, and the magnitude of the current generated by the above-mentioned multiple electronic elements (not shown) is adjusted based on the output voltage of each sensor 25. This makes it possible to stabilize the current supplied to the motor 2 at a desired current value, and to stabilize the operation of the power conversion device 10 and the motor module 1.
  • the shield core 40 collects the magnetic field generated by the current flowing through the bus bar 30 and blocks external magnetic fields.
  • the shield core 40 is magnetic.
  • the shield core 40 is composed of multiple magnetic metal plates stacked in the plate thickness direction.
  • the shield core 40 is composed of multiple magnetic metal plates stacked in the first direction D1.
  • Metal materials with high magnetic permeability such as ferrite and permalloy can be used as materials for the shield core 40.
  • the shield core 40 has a first wall portion 40a, a second wall portion 40b, and a third wall portion 40c.
  • the first wall portion 40a is a plate extending in a direction perpendicular to the third direction D3.
  • the plate surface of the first wall portion 40a faces the third direction D3.
  • the first wall portion 40a is a rectangle whose long side extends in the second direction D2.
  • the first wall portion 40a is disposed below the sensor 25 and the bus bar 30 (+D3 side).
  • the surface of the first wall portion 40a facing the lower side (+D3 side) contacts the support surface 12d. That is, the shield core 40 contacts the support surface 12d.
  • the first wall portion 40a is disposed between a pair of positioning surfaces 13a, 13b.
  • the second wall portion 40b and the third wall portion 40c are connected to both ends of the first wall portion 40a in the second direction D2, respectively.
  • the second wall portion 40b is a plate-like member that protrudes upward (towards -D3) from the left end (+D2 side) of the first wall portion 40a.
  • the plate surface of the second wall portion 40b faces the second direction D2.
  • the upper end of the second wall portion 40b is located above the sensor 25.
  • the second wall portion 40b is disposed between a pair of positioning surfaces 13a, 13b.
  • the third wall portion 40c is a plate-like member that protrudes upward (toward -D3) from the right end (-D2 side) of the first wall portion 40a.
  • the plate surface of the third wall portion 40c faces the second direction D2.
  • the upper end of the third wall portion 40c is located above the sensor 25.
  • the third wall portion 40c is disposed between the pair of positioning surfaces 13a, 13b.
  • the first wall portion 40a and the second wall portion 40b are disposed between the pair of positioning surfaces 13a, 13b. Therefore, the shield core 40 is disposed between the pair of positioning surfaces 13a, 13b.
  • the second wall portion 40b and the third wall portion 40c sandwich the bus bar 30, the board protruding portion 20d, and the sensor 25 mounted on the board protruding portion 20d from both sides in the second direction D2.
  • the power conversion device 10 includes a plurality of shield cores 40.
  • the shield cores 40 are arranged in line in the second direction D2.
  • One sensor 25 and one bus bar 30 are arranged inside one shield core 40.
  • Each of the plurality of shield cores 40 surrounds one sensor 25 and one bus bar 30 from both sides (+D2 side and -D2 side) of the second direction D2 and one side (+D3 side) of the third direction D3. Therefore, according to this embodiment, the magnetic field generated by the current flowing through one bus bar 30 is collected by the shield core 40 surrounding the bus bar 30. Therefore, it is possible to prevent the magnetic field generated by the current flowing through one bus bar 30 from passing through the sensor 25 that detects the current value flowing through the other bus bar 30. Therefore, it is possible to improve the accuracy with which each sensor 25 detects the current value flowing through each bus bar 30, and therefore the operation of the power conversion device 10 and the motor module 1 can be stabilized.
  • the support portion 12 has a support surface 12d facing upward, i.e., the other side (-D3 side) of the third direction D3, and the shield core 40 contacts the support surface 12d. Therefore, the position of the shield core 40 in the third direction D3 relative to the support portion 12 can be determined with high precision. Therefore, since the position of each shield core 40 relative to the sensor 25 and the bus bar 30 in the third direction D3 can be determined with high precision, the precision with which each sensor 25 detects the value of the current flowing through each bus bar 30 can be more suitably improved.
  • the support portion 12 is grounded via the case 11 as described above. Therefore, in this embodiment, the radiation noise radiated from each bus bar 30 can be suitably transmitted to the earth via each shield core 40. This makes it possible to suppress radiation noise from being radiated from each shield core 40. Therefore, it is possible to suppress the superposition of radiation noise on each sensor 25, and it is possible to improve the accuracy with which each sensor 25 detects the current value flowing through each bus bar 30. Therefore, it is possible to stabilize the operation of the power conversion device 10 and the motor module 1. Furthermore, it is possible to suppress the superposition of radiation noise on each of the circuit board 20 and the IGBT module 16, so it is possible to stabilize the operation of each of the circuit board 20 and the IGBT module 16.
  • the surface of the first wall portion 40a of the shield core 40 facing the lower side (+D3 side) is in contact with the support surface 12d.
  • the shield core 40 and the support portion 12 are in surface contact, the contact area between the shield core 40 and the support portion 12 can be increased, and the impedance between the shield core 40 and the earth can be reduced. Therefore, the radiated noise radiated from the bus bar 30 and the radiated noise radiated from the electrical equipment arranged around the power conversion device 10 can be suitably transmitted to the earth via the shield core 40. Therefore, the radiated noise can be prevented from being superimposed on each sensor 25, and the operation of the power conversion device 10 and the motor module 1 can be stabilized.
  • the shape of the shield core 40 as viewed in the first direction D1 is not limited to that of this embodiment, and may be another shape, such as a U-shape protruding downward (+D3 side).
  • the shield core 40 may be structured to surround the sensor 25 and bus bar 30 not only on both sides in the second direction D2 and one side in the third direction D3 (+D3 side), but also from the other side in the third direction (-D3 side).
  • the shield core 40 is, for example, rectangular as viewed in the first direction D1.
  • the core sealing portion 50 is disposed inside the housing portion 12c of the support portion 12.
  • the core sealing portion 50 is made of resin.
  • the core sealing portion 50 seals the lower portion of the shield core 40 with resin. That is, the core sealing portion 50 seals at least a part of the shield core 40 with resin. At least a part of the shield core 40 is embedded inside the core sealing portion 50.
  • the core sealing portion 50 contacts each of the inner surfaces of the housing portion 12c, the surface facing the first direction D1 and the surface facing the second direction D2.
  • the core sealing portion 50 contacts a part of the support surface 12d, the inner surface of the housing portion 12c, facing the third direction D3.
  • the core sealing portion 50 is fixed to the housing portion 12c. Therefore, each shield core 40 is fixed to the support portion 12 via the core sealing portion 50.
  • seal means to fill a gap or to embed an object. Therefore, the word “seal” is also used when the passage of liquids such as moisture is not permitted.
  • the power conversion device 10 and the motor module 1 of this embodiment include a magnetic shield core 40 that surrounds the bus bar 30 and the sensor 25 from both sides in the second direction D2 and one side (+D3 side) in the third direction D3, a core sealing portion 50 that seals at least a portion of the shield core 40 with resin, and a support portion 12, and the shield core 40 is fixed to the support portion 12 via the core sealing portion 50.
  • the shield core in a configuration in which the shield core is assembled to a resin support portion or the like by press-fitting, depending on the dimensional tolerance of the shield core, the shield core may not be assembled to the support portion or the like. In this case, the shield core must be discarded, and the manufacturing cost of the power conversion device increases.
  • the shield core 40 at least a portion of which is sealed in the core sealing portion 50, is fixed to the support portion 12 via the core sealing portion 50, so that even a shield core with a large dimensional tolerance can be easily fixed to the support portion 12. Therefore, it is possible to use a shield core 40 with a large dimensional tolerance, which helps prevent an increase in the manufacturing steps and manufacturing costs of the power conversion device 10 and motor module 1.
  • the shield core 40 at least a portion of which is sealed in the core sealing part 50, is fixed to the support part 12 via the core sealing part 50, so that the shield core 40 can be easily fixed to the support part 12. Therefore, it is possible to more suitably suppress an increase in the labor hours for fixing the shield core 40 to the support part 12, and it is possible to suppress an increase in the labor hours for manufacturing the power conversion device 10 and the motor module 1.
  • the upper side of the support portion 12, i.e., the surface facing the other side (-D3 side) of the third direction D3, is provided with a housing portion 12c recessed toward the lower side, i.e., toward one side (+D3 side) of the third direction D3, and the core sealing portion 50 contacts the inner surface of the housing portion 12c.
  • This makes it possible to more firmly fix the shield core 40 to the support portion 12 via the core sealing portion 50, and therefore the position of each shield core 40 relative to each sensor 25 and each bus bar 30 can be stabilized. This makes it possible to more suitably improve the accuracy with which each sensor 25 detects the current value flowing through each bus bar 30.
  • the shield core fixing process Ps is part of the manufacturing process of the power conversion device 10 and the motor module 1.
  • the shield core fixing process Ps includes a positioning step S1 for determining the position of the shield core 40 relative to the support portion 12 in a mold 80, and a molding step S2 for sealing at least a part of the shield core 40 with resin by injection molding using the support portion 12 and the shield core 40 as insert members, and for molding the core sealing portion 50 fixed to the support portion 12.
  • the term "workers, etc.” includes workers who perform each task and assembly equipment, etc. Each task may be performed only by a worker, only by an assembly equipment, or by a worker and an assembly equipment.
  • the worker or the like determines the position of the shield core 40 relative to the support portion 12 within the mold 80. As shown in FIG. 5B, the worker or the like first places each shield core 40 between a pair of positioning surfaces 13a, 13b of the support portion 12. This determines the position of each shield core 40 in the second direction D2 relative to the support portion 12. In addition, the surface of each shield core 40 facing the lower side (+D3 side) of the first wall portion 40a contacts the support surface 12d, so the position of each shield core 40 in the third direction D3 relative to the support portion 12 is determined.
  • the mold 80 is composed of an upper mold 81 and a lower mold 82.
  • the lower mold 82 is a roughly rectangular parallelepiped with a lower storage section 82a that is recessed downward (+D3 side) from the surface facing upward (-D3 side).
  • the worker or the like inserts the lower part of the support part 12 into the lower storage section 82a, and attaches the lower mold 82 to the support part 12.
  • the upper mold 81 is a generally rectangular parallelepiped with a first storage portion 81b recessed upward from its downward surface.
  • the outer edge of the downward surface of the first storage portion 81b contacts the upper surface 12a of the support portion 12 in the third direction D3. This determines the position of the upper mold 81 in the third direction D3 relative to the support portion 12.
  • the other part of the downward surface of the first storage portion 81b faces the support surface 12d and the multiple positioning portions 13 at intervals in the third direction D3.
  • the upper mold 81 is provided with an injection port 81a and multiple second storage portions 81c.
  • the injection port 81a is a hole that penetrates the upper mold 81 in the third direction D3.
  • the injection port 81a is provided at approximately the center of the upper mold 81 in the second direction D2.
  • the injection port 81a is located above approximately the center of the support portion 12 in the second direction D2.
  • Each of the multiple second storage portions 81c is a hole recessed upward (towards -D3) from the downward facing surface of the first storage portion 81b.
  • six second storage portions 81c are provided.
  • the multiple second storage portions 81c are provided at intervals along the second direction D2.
  • the upper mold 81 has six pairs of opposing parts that face each other in the first direction D1. Between each pair of opposing parts, one of the second wall part 40b or the third wall part 40c of each shield core 40 is disposed. This determines the position of each shield core 40 in the first direction D1 relative to the support part 12 and the mold 80, and the positioning step S1 is completed.
  • the worker or the like performs injection molding using the support portion 12 and the shield core 40 as insert members to mold the core sealing portion 50.
  • the worker or the like pours the thermally melted molten resin MR into the interior of the mold 80 from the injection port 81a of the upper mold 81.
  • the resin is an acrylate-based thermosetting resin.
  • the resin may be other resins such as epoxy-based thermosetting resins.
  • the injection pressure for pouring the molten resin MR into the mold 80 is a low pressure of about 0.5 to 15.0 MPa. The molten resin MR poured into the mold 80 flows toward both sides in the second direction D2 inside the accommodation portion 12c.
  • the worker or the like stops the injection of the molten resin MR. After that, the worker heats the molten resin MR to a predetermined temperature using a heater (not shown) or the like to harden the resin, and then removes the mold 80 from the support portion 12. As a result, as shown in FIG. 5D, the core sealing portion 50 is formed, which seals at least a portion of each shield core 40 with resin. In addition, the outer surface of the core sealing portion 50 contacts the inner surface of the housing portion 12c, so that the core sealing portion 50 is fixed to the support portion 12.
  • the manufacturing method for the power conversion device of this embodiment includes a positioning step S1 in which the position of the shield core 40 is determined relative to the support portion 12 in the mold 80, and a molding step S2 in which at least a portion of the shield core 40 is sealed with resin by injection molding using the support portion 12 and the shield core 40 as insert members, and a core sealing portion 50 is molded to be fixed to the support portion 12. Therefore, the shield core 40 can be fixed to the support portion 12 via the core sealing portion 50.
  • the shield core may not be assembled to the support portion or the like, and the shield core may have to be discarded.
  • the shield core 40 at least a portion of which is sealed in the core sealing portion 50 by injection molding using the support portion 12 and the shield core 40 as insert members, is fixed to the support portion 12 via the core sealing portion 50, so that even a shield core 40 with a large dimensional tolerance can be easily fixed to the support portion 12. Therefore, it is possible to use a shield core 40 with a large dimensional tolerance, which helps prevent an increase in the manufacturing steps and manufacturing costs of the power conversion device 10 and motor module 1.
  • the shield core 40 is fixed to the support portion 12 by injection molding using the support portion 12 and the shield core 40 as insert members, so that the shield core 40 can be easily fixed to the support portion 12. Therefore, an increase in the labor required for the shield core fixing process Ps can be more effectively suppressed.
  • the support portion 12 has a pair of positioning surfaces 13a, 13b facing each other in the second direction D2, and the shield core 40 is disposed between the pair of positioning surfaces 13a, 13b. Therefore, in molding step S2, it is possible to prevent each shield core 40 from moving in the second direction D2 due to the pressure from the resin flowing into the mold 80.
  • This increases the positional accuracy of each shield core 40 relative to the support portion 12, thereby increasing the positional accuracy of each shield core 40 relative to each sensor 25 and each bus bar 30. This makes it possible to more suitably increase the accuracy with which each sensor 25 detects the value of the current flowing through the bus bar 30.
  • a gap is provided between each of the pair of positioning surfaces 13a, 13b and the inner surface of the accommodating portion 12c in the first direction D1. Therefore, in the molding step S2, the molten resin MR can flow stably through the gap toward both sides in the second direction D2. Also, in this embodiment, a gap is provided between each shield core 40 and the inner surface of the accommodating portion 12c in the first direction D1. Therefore, the molten resin MR can easily flow in the second direction D2 through between the shield core 40 and the inner surface of the accommodating portion 12c.
  • the molten resin MR can be stably filled into the entire inside of the accommodating portion 12c, so that a part of the shield core 40 can be stably sealed by the core sealing portion 50. Also, since the contact area between the core sealing portion 50 and the inner surface of the accommodating portion 12c can be stabilized, the core sealing portion 50 can be firmly fixed to the support portion 12. Therefore, each shield core 40 can be firmly fixed to the support portion 12, so the positional accuracy of each shield core 40 relative to each sensor 25 and each bus bar 30 can be stabilized, and the accuracy with which each sensor 25 detects the current value flowing through the bus bar 30 can be more suitably improved.
  • the injection pressure for pouring the molten resin MR into the mold 80 in the molding step S2 is low, at 0.5 to 15.0 MPa, so that the load applied to the shield core 40 by the resin flowing into the mold 80 can be reduced. Therefore, fluctuations in the magnetic properties of the shield core 40 can be suppressed, and the strength of the magnetic field collected by the shield core 40 can be stabilized. This makes it possible to more suitably improve the accuracy with which each sensor 25 detects the value of the current flowing through the bus bar 30.
  • Fig. 6A is a top view showing a power conversion device 210 and a part of a motor module 201 according to the first modification of the first embodiment described above.
  • Fig. 6B is a cross-sectional view showing the power conversion device 210 according to the first modification of the first embodiment.
  • the same components as those in the first embodiment described above are denoted by the same reference numerals, and the description thereof will be omitted.
  • the support portion 212 does not have a storage portion, and the upper surface 212a, which is the surface of the support portion 212 facing upward (-D3 side), is flat and extends in a direction perpendicular to the third direction D3.
  • the surface of the first wall portion 40a of each shield core 40 facing downward (+D3 side) comes into contact with the upper surface 212a.
  • the upper surface 212a faces upward, i.e., the other side of the third direction D3, and serves as the support surface 212d that comes into contact with the shield core 40.
  • the core sealing portion 250 of this modified example is substantially rectangular.
  • the core sealing portion 250 seals at least a portion of each shield core 40 with resin.
  • the core sealing portion 250 covers the entire support surface 212d.
  • the surface of the core sealing portion 250 facing downward is in contact with the support surface 212d.
  • the core sealing portion 250 is fixed to the support portion 212, and the shield core 40 is fixed to the support portion 212 via the core sealing portion 250. Therefore, according to this modified example, even a shield core with a large dimensional tolerance can be easily fixed to the support portion 212. Therefore, it is possible to suppress an increase in the manufacturing man-hours and manufacturing costs of the power conversion device 210 and the motor module 201.
  • the support portion 212 is connected to the bottom wall portion 211a of the case 211.
  • the support portion 212 is a part of the case 211. Therefore, according to this modified example, it is possible to suppress an increase in the manufacturing labor and number of parts of the power conversion device 210 compared to a case in which the support portion 212 is provided separately from the case 211 and fixed to the case 211 by screws or the like.
  • Fig. 7A is a top view showing a power conversion device 310 and a part of a motor module 301 according to Modification 2 of the first embodiment described above.
  • Fig. 7B is a cross-sectional view showing a power conversion device 310 according to Modification 2 of the first embodiment.
  • the same components as those in the first embodiment described above are denoted by the same reference numerals, and description thereof will be omitted.
  • the core sealing portion 350 of this modified example seals at least a portion of each of the multiple shield cores 40 with resin.
  • the core sealing portion 350 contacts the inner surface of the accommodating portion 12c and is fixed to the support portion 12.
  • each shield core 40 is fixed to the support portion 12 via the core sealing portion 350.
  • the core sealing portion 350 is provided with a notch 350a.
  • the notch 350a is provided in the core sealing portion 350 in a portion between adjacent shield cores 40 in the second direction D2. That is, the notch 350a is provided in the core sealing portion 350 in a portion between multiple shield cores 40.
  • the notch 350a is provided by configuring the shape of the inner surface of the mold used in the above-mentioned shield core fixing process Ps to a shape corresponding to the shape of the notch 350a.
  • the notch 350a is configured by a first notch 350b and a second notch 350c.
  • the first cutout 350b is the rear (+D1) portion of the cutout 350a. As shown in FIG. 7B, the first cutout 350b is recessed downward from the surface of the core sealing portion 350 facing the upper side (-D3 side), that is, toward one side (+D3 side) in the third direction D3.
  • the second notch 350c is the front (-D1 side) portion of the notch 350a.
  • the second notch 350c is connected to the first notch 350b in the first direction D1.
  • the second notch 350c is recessed from the surface of the core sealing part 350 facing the front to the rear, i.e., to one side (+D1 side) in the first direction D1.
  • the lower end of the second notch 350c is connected to the surface of the core sealing part 350 facing downward.
  • a second notch (notch) 350c recessed in the first direction D1 and a first notch (notch) 350b recessed in the third direction D3 are provided in the portion of the core sealing portion 350 between the multiple shield cores 40. This allows the volume of the core sealing portion 350 to be reduced, thereby reducing the material cost of the resin that constitutes the core sealing portion 350. This allows the manufacturing costs of the power conversion device 310 and the motor module 301 to be reduced.
  • the shape of the cutout is not limited to that of this modified example, and for example, the first cutout recessed in the third direction D3 may be provided further forward (-D1 side) than the second cutout recessed in the first direction D1. Also, either the first cutout or the second cutout may not be provided. In this case, the cutout is recessed in either the first direction D1 or the third direction D3.
  • Fig. 8A is a top view showing a power conversion device 410 and a part of a motor module 401 according to Modification 3 of the first embodiment described above.
  • Fig. 8B is a cross-sectional view showing the power conversion device 410 according to Modification 3 of the first embodiment.
  • the same components as those in the first embodiment described above are denoted by the same reference numerals, and description thereof will be omitted.
  • the core sealing portion 450 of this modified example seals at least a portion of each of the multiple shield cores 40 with resin.
  • the core sealing portion 450 contacts the inner surface and upper surface 12a of the accommodating portion 12c and is fixed to the support portion 12.
  • each shield core 40 is fixed to the support portion 12 via the core sealing portion 450.
  • the core sealing portion 450 of this modified example is composed of a first portion 450a, a second portion 450b, multiple third portions 450c, and multiple fourth portions 450d.
  • the surface of the second wall portion 40b of each shield core 40 facing the left side (+D2 side) is referred to as the outer surface of the second wall portion 40b
  • the surface of the third wall portion 40c of each shield core 40 facing the right side (-D2 side) is referred to as the outer surface of the third wall portion 40c
  • the surface of the second wall portion 40b of each shield core 40 facing to the right is called the inner surface of the second wall portion 40b
  • the surface of the third wall portion 40c of each shield core 40 facing to the left is called the inner surface of the third wall portion 40c.
  • the outer surface of the second wall portion 40b and the outer surface of the third wall portion 40c of each shield core 40 are the outer surfaces of each shield core 40.
  • the inner surface of the second wall portion 40b and the inner surface of the third wall portion 40c of each shield core 40 are the inner surfaces of each shield core 40.
  • the first portion 450a is a portion of the core sealing portion 450 that is located to the left of the outer surface of the second wall portion 40b of the shield core 40D that is located on the leftmost side (+D2 side).
  • the position of the upper end portion (-D3 side) of the first portion 450a is the same as the position of the upper end portion of the second wall portion 40b.
  • the first portion 450a contacts the entire outer surface of the second wall portion 40b of the shield core 40D. In other words, the first portion 450a contacts the outer surface of the shield core 40D.
  • the second portion 450b is a portion of the core sealing portion 450 located to the right of the outer surface of the third wall portion 40c of the shield core 40E that is located at the rightmost side (-D2 side).
  • the position of the upper end portion (-D3 side) of the second portion 450b is the same as the position of the upper end portion of the third wall portion 40c.
  • the second portion 450b contacts the entire outer surface of the third wall portion 40c of the shield core 40E. In other words, the second portion 450b contacts the outer surface of the shield core 40E.
  • each of the multiple third parts 450c is a part of the core sealing portion 450 located between the shield cores 40 adjacent to each other in the second direction D2.
  • two third parts 450c are provided.
  • the position of the upper end (-D3 side) of each third part 450c is the same as the position of the upper end of the second wall portion 40b and the upper end of the third wall portion 40c.
  • One third part 450c contacts the entire outer surface of the third wall portion 40c of the shield core 40D and the entire outer surface of the second wall portion 40b of the shield core 40F arranged adjacent to the shield core 40D in the second direction D2.
  • the other third part 450c contacts the entire outer surface of the third wall portion 40c of the shield core 40F and the entire outer surface of the second wall portion 40b of the shield core 40E. That is, the multiple third portions 450c come into contact with the outer surface of the shield core 40.
  • each of the multiple fourth portions 450d is a portion located between the outer surface of the second wall portion 40b and the outer surface of the third wall portion 40c of each shield core 40.
  • three fourth portions 450d are provided.
  • the position of the upper end (-D3 side) of each fourth portion 450d is located lower (+D3 side) than the positions of the upper end of the second wall portion 40b and the upper end of the third wall portion 40c.
  • Each fourth portion 450d is disposed below the bus bar 30. Therefore, the upper ends of the first portion 450a, the second portion 450b, and the third portion 450c are located higher than the upper end of the fourth portion 450d.
  • Each fourth portion 450d contacts the lower portion of the inner surface of the second wall portion 40b and the lower portion of the inner surface of the third wall portion 40c of each shield core 40. That is, the multiple fourth portions 450d come into contact with the inner surface of the shield core 40.
  • the upper ends of the first portion 450a, the second portion 450b, and the third portion 450c which are the portions of the core sealing portion 450 that contact the outer surfaces of the multiple shield cores 40, i.e., the ends on the other side (-D3 side) of the third direction D3, are located higher than the upper end of the fourth portion 450d that contacts the inner surfaces of the multiple shield cores 40.
  • Fig. 9A is a top view showing a power conversion device 510 and a part of a motor module 501 according to Modification 4 of the first embodiment described above.
  • Fig. 9B is a cross-sectional view showing a power conversion device 510 according to Modification 4 of the first embodiment.
  • the same components as those in the first embodiment described above are denoted by the same reference numerals, and description thereof will be omitted.
  • each shield core 40 is disposed at a distance from the support surface 12d in the third direction D3. Also, the second wall portion 40b and the third wall portion 40c of each shield core 40 are disposed at a distance from the pair of positioning surfaces 13a, 13b in the second direction D2. In other words, each shield core 40 is disposed at a distance from the support portion 12.
  • the first wall portion 40a can be fixed to the support surface 12d via a portion of the core sealing portion 550 that is located between the first wall portion 40a of each shield core 40 and the support surface 12d of the support portion 12 in the third direction D3. Therefore, each shield core 40 can be more firmly fixed to the support portion 12 via the core sealing portion 550, and the accuracy with which each sensor 25 detects the value of the current flowing through each bus bar 30 can be stabilized.
  • the use of the power conversion device of this embodiment is not limited to generating power to be supplied to a motor that drives a vehicle, but may also generate power to be supplied to a motor mounted on an electrical appliance or the like.
  • the power conversion device may be an inverter that generates AC current of a predetermined waveform from DC current supplied from an external power source, or a converter that generates DC current from AC current supplied from an external power source.
  • the configuration of the support part is not limited to that of this embodiment, and for example, the support part does not need to be provided with a pair of positioning surfaces.
  • a pair of positioning surfaces can be provided on the inner surface of the mold used in the shield core fixing process Ps, and the position of the shield core relative to the support part can be determined by the pair of positioning surfaces.
  • a portion of the busbar may be embedded inside the core sealing portion.
  • the busbar in the shield core fixing process, is injection molded as a part of the insert member, so that a portion of the busbar can be embedded inside the core sealing portion.
  • a hole may be provided in the core sealing portion after molding, and the busbar may be passed through the hole.
  • the number of bus bars, sensors, and shield cores included in the power conversion device is not limited to three, but may be one or two, or four or more.
  • a case has been described in which a sensor is mounted on a board protrusion that protrudes in one direction from an edge of a circuit board, and the board protrusion is disposed between the second wall and the third wall of the shield core.
  • a pair of holes for inserting the second wall and the third wall of the shield core, respectively, may be provided in the circuit board, and the sensor may be mounted between the pair of holes.
  • a power conversion device including a bus bar extending in a first direction, a sensor that detects a magnetic field generated by a current flowing through the bus bar, a magnetic shield core that surrounds the bus bar and the sensor from both sides in a second direction perpendicular to the first direction and from at least one side in a third direction perpendicular to the first direction and the second direction, a core sealing portion that seals at least a part of the shield core with resin, and a support portion, wherein the shield core is fixed to the support portion via the core sealing portion.
  • the power conversion device according to any one of (1) to (4), wherein the support portion has a support surface facing the other side of the third direction, and the shield core is in contact with the support surface.
  • the shield core is arranged with a gap between it and the support portion.
  • the power conversion device comprising: a plurality of the bus bars, a plurality of the sensors, and a plurality of the shield cores arranged side by side in the second direction, and each of the plurality of the shield cores surrounds one of the sensors and one of the bus bars from both sides in the second direction and at least one side in the third direction.
  • the power conversion device in which the core sealing portion seals a portion of each of the plurality of shield cores with resin, and a notch recessed in the first direction or the third direction is provided in a portion of the core sealing portion between the plurality of shield cores.
  • the power conversion device in which the core sealing portion seals a portion of each of the plurality of shield cores with resin, and an end portion on the other side in the third direction of a portion of the core sealing portion that contacts an outer surface of each of the plurality of shield cores is located on the other side in the third direction of an end portion on the other side in the third direction of a portion of the core sealing portion that contacts an inner surface of each of the plurality of shield cores.
  • a method for manufacturing a power conversion device that includes a magnetic shield core, a resin core sealing part, and a support part, the method including a positioning step for determining the position of the shield core relative to the support part in a mold, and a molding step for molding the core sealing part that is fixed to the support part and at least a part of the shield core is sealed with resin by injection molding using the support part and the shield core as insert members.

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PCT/JP2023/038815 2022-10-31 2023-10-27 電力変換装置、モータモジュール、および電力変換装置の製造方法 Ceased WO2024095903A1 (ja)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0865945A (ja) * 1994-08-26 1996-03-08 Aqueous Res:Kk モータ駆動装置
JPH09304447A (ja) * 1996-05-10 1997-11-28 Denso Corp 電流検出装置
JP2015049184A (ja) * 2013-09-03 2015-03-16 Tdk株式会社 インバータ装置
WO2018159229A1 (ja) * 2017-02-28 2018-09-07 パナソニックＩｐマネジメント株式会社 電流検出装置
WO2022024610A1 (ja) * 2020-07-28 2022-02-03 アルプスアルパイン株式会社 電流センサ

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0865945A (ja) * 1994-08-26 1996-03-08 Aqueous Res:Kk モータ駆動装置
JPH09304447A (ja) * 1996-05-10 1997-11-28 Denso Corp 電流検出装置
JP2015049184A (ja) * 2013-09-03 2015-03-16 Tdk株式会社 インバータ装置
WO2018159229A1 (ja) * 2017-02-28 2018-09-07 パナソニックＩｐマネジメント株式会社 電流検出装置
WO2022024610A1 (ja) * 2020-07-28 2022-02-03 アルプスアルパイン株式会社 電流センサ

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