WO2024171848A1 - パワーモジュール、パワーモジュールの製造方法、および電力変換装置 - Google Patents

パワーモジュール、パワーモジュールの製造方法、および電力変換装置 Download PDF

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Publication number
WO2024171848A1
WO2024171848A1 PCT/JP2024/003469 JP2024003469W WO2024171848A1 WO 2024171848 A1 WO2024171848 A1 WO 2024171848A1 JP 2024003469 W JP2024003469 W JP 2024003469W WO 2024171848 A1 WO2024171848 A1 WO 2024171848A1
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WIPO (PCT)
Prior art keywords
recess
nut
bolt
main
terminal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2024/003469
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English (en)
French (fr)
Japanese (ja)
Inventor
剛 濱田
正喜 後藤
達志 森貞
隼人 寺田
穂隆 六分一
羽香奈 増田
泰之 三田
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to CN202480011886.1A priority Critical patent/CN120677567A/zh
Priority to JP2025501060A priority patent/JPWO2024171848A1/ja
Publication of WO2024171848A1 publication Critical patent/WO2024171848A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W40/00—Arrangements for thermal protection or thermal control
    • H10W40/10—Arrangements for heating
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
    • H10W90/00—Package configurations

Definitions

  • This disclosure relates to a power module, a method for manufacturing a power module, and a power conversion device.
  • Patent Document 1 discloses a heat sink-integrated power module having a power module section, a fin base, and heat dissipation fins.
  • the power module section includes a module base, a power semiconductor element mounted on the module base, and a molded section that seals the power semiconductor element.
  • the fin base includes a heat dissipation diffusion section to which the heat dissipation fins are attached, and a base section that is formed on the heat dissipation diffusion section and to which the module base is joined.
  • the module base is provided with a first uneven section
  • the base section is provided with a second uneven section that fits into the first uneven section.
  • the present disclosure therefore aims to provide a technology that can reduce the stress applied to the interface between the main terminal and the molded part when connecting the main terminal and bus bar using bolts and nuts in a power module with an integrated heat sink.
  • the power module comprises a semiconductor element, a frame having the semiconductor element mounted on one side thereof, a module base having the frame disposed on one side thereof, a main terminal which is a part of the frame, a molded portion which seals the semiconductor element, the frame, and the module base so that the main terminal is exposed, a base portion which is integrated with the other side of the module base exposed from the molded portion, a heat sink having a plurality of heat dissipation fins which protrude from the base portion on the side opposite the module base, and a bolt fastened to a first main surface of the main terminal or a second main surface opposite the first main surface.
  • a recess is formed on the main terminal side of the structural member in which the head of the nut or bolt can be disposed, the bolt that screws into the nut disposed in the recess or the nut that screws into the bolt disposed in the recess is disposed on the opposite side of the structural member from the external terminal, and a rotation suppressing portion that suppresses rotation of the head of the nut or bolt disposed in the recess is provided on the inner surface of the recess.
  • the nut or bolt arranged in the recess can move toward the main terminal. Therefore, the main terminal is displaced until the bolt or nut arranged on the opposite side of the structural member to the external terminal contacts the nut or bolt arranged in the recess, but when the bolt or nut arranged on the opposite side of the structural member to the external terminal contacts the nut or bolt arranged in the recess, the main terminal does not displace any further and the nut or bolt arranged in the recess moves toward the main terminal.
  • the displacement applied to the main terminal when the main terminal and external terminal are connected using the bolt and nut is limited to the clearance between the bolt and the nut.
  • FIG. 1 is a cross-sectional view of a power module according to a first embodiment.
  • FIG. 2 is a top view of the power module according to the first embodiment.
  • FIG. 13 is a top view of a power module according to a modified example of the first embodiment.
  • 10 is a cross-sectional view showing a connection between a main terminal and a bus bar provided in a power module according to a modified example of the first embodiment.
  • FIG. FIG. 13 is a top view of a power module according to a modified example of the first embodiment.
  • FIG. 13 is a top view of a power module according to a modified example of the first embodiment.
  • 4 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in the power module according to the first embodiment.
  • FIG. 4 is a top view showing a connection by bolt fastening between a main terminal and a bus bar provided in the power module according to the first embodiment.
  • FIG. 4 is a cross-sectional view showing a clearance between a main terminal and a terminal block provided in the power module according to the first embodiment.
  • FIG. 1 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar when a clearance exists between the main terminal and the terminal block of the power module according to the first embodiment.
  • FIG. 11 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a modified example of the first embodiment.
  • FIG. 1 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a modified example of the first embodiment.
  • FIG. FIG. 2 is a top view of a terminal block and a nut provided in the power module according to the first embodiment.
  • FIG. 13 is a top view of a terminal block and a nut provided in the power module according to the modified example of the first embodiment.
  • FIG. 13 is a top view of a terminal block and a nut provided in the power module according to the modified example of the first embodiment.
  • FIG. 13 is a top view of a terminal block and a nut provided in the power module according to the modified example of the first embodiment.
  • FIG. 13 is a top view of a terminal block and a nut provided in the power module according to the modified example of the first embodiment.
  • FIG. 13 is a top view of a terminal block and a nut provided in the power module according to the modified example of the first embodiment.
  • 4 is a cross-sectional view showing a connection by bolt fastening between a terminal block and a heat sink provided in the power module according to the first embodiment.
  • FIG. 1 is a top view showing a connection by bolt fastening between a terminal block and a heat sink provided in the power module according to the first embodiment.
  • FIG. 11 is a cross-sectional view showing a connection by solder between a terminal block and a heat sink provided in a power module according to a modified example of the first embodiment.
  • FIG. 13 is a cross-sectional view showing a connection by welding between a terminal block and a heat sink provided in a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view showing a connection by crimping between a terminal block and a heat sink provided in a power module according to a modified example of the first embodiment.
  • FIG. 13 is a cross-sectional view showing the arrangement of a terminal block having a positioning structure provided in a power module according to a modified example of the first embodiment.
  • FIG. 1A to 1C are a cross-sectional view, a side view, and a top view showing the arrangement of a terminal block having a positioning structure provided in a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view of a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view of a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view of a power module according to a modified example of the first embodiment.
  • FIG. 11 is a cross-sectional view of a power module according to a second embodiment.
  • 11 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a second embodiment.
  • FIG. 11 is a top view of a terminal block, a nut, and a nut fall-off prevention member provided in a power module according to a second embodiment.
  • FIG. 11 is a top view of a terminal block, a nut, and a nut fall-off prevention member provided in a power module according to a second embodiment.
  • FIG. 13 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a modified example of embodiment 2.
  • FIG. FIG. 11 is a cross-sectional view of a power module according to a third embodiment. 11 is a cross-sectional view showing a state before bolt fastening between a main terminal and a bus bar provided in a power module according to embodiment 3.
  • FIG. 11 is a cross-sectional view showing a connection by bolt fastening between a main terminal and a bus bar provided in a power module according to a third embodiment.
  • FIG. FIG. 11 is a top view of a terminal block, a nut, and a nut fall-off prevention member provided in a power module according to embodiment 3.
  • FIG. 13 is a cross-sectional view showing a state before bolt fastening of a main terminal and a bus bar provided in a power module according to a modified example of embodiment 3.
  • FIG. 13 is a cross-sectional view showing a state before bolt fastening of a main terminal and a bus bar provided in a power module according to a modified example of embodiment 3.
  • FIG. 13 is a block diagram showing a configuration of a power conversion system to which a power conversion device according to a fourth embodiment is applied.
  • Fig. 1 is a cross-sectional view of a power module 202 according to the first embodiment.
  • Fig. 2 is a top view of the power module 202 according to the first embodiment.
  • the power module 202 is a heat sink integrated power module, and includes a power module section 9 and a heat sink 16.
  • the power module section 9 includes a plurality of semiconductor chips 1 (semiconductor elements), a lead frame 3 (frame), an insulating sheet 4, a module base 5, a molded section 8, and a plurality of bus bars 10 (external terminals).
  • a terminal block is disposed on the heat sink 16. The terminal block is characterized in that the nut is prevented from rotating and is mounted in a state in which it can move between the main terminal 7 side and the heat sink 16 side.
  • Multiple semiconductor chips 1 are mounted on the upper surface (one side) of a lead frame 3.
  • the lead frame 3 is arranged via an insulating sheet 4 that is attached to the upper surface (one side) of a module base 5.
  • the molded part 8 is made of a resin-based material, and seals the semiconductor chips 1, lead frame 3, insulating sheet 4, and module base 5 so that the main terminals 7, which are part of the lead frame 3, and the lower surface (other side) of the module base 5 are exposed.
  • the heat sink 16 has a base portion 14 integrated with the lower surface (the other surface) of the module base 5, and a plurality of heat dissipation fins 15 protruding downward from the base portion 14 (the side opposite the module base 5).
  • a plurality of concave mating portions 5a are provided on the lower surface (the other surface) of the module base 5.
  • a plurality of convex mated portions 14a that can matingly engage with the mating portions 5a are provided on the upper surface (the surface facing the module base 5) of the base portion 14.
  • the module base 5 and the heat sink 16 are integrated by mating the mating portions 5a with the mated portions 14a.
  • the mating portions 5a and the mated portions 14a may be provided continuously or intermittently in the depth direction of the module base 5 and the base portion 14, respectively. Furthermore, the unevenness of the mating portion 5a of the module base 5 and the mated portion 14a of the base portion 14 of the heat sink 16 is not limited to this, and the same effect can be obtained even if the mating portion 5a of the module base 5 is convex or the mated portion 14a of the base portion 14 of the heat sink 16 is concave.
  • the heat sink 16 is formed in a rectangular shape when viewed from above.
  • Two terminal blocks 13 (structural members) are fixed to both ends of the base portion 14 of the heat sink 16. Each terminal block 13 is disposed between the main terminal 7 and the base portion 14.
  • molding is performed to form terminals, forming the control terminals 6 and main terminals 7, which are part of the lead frame 3.
  • molding to form the terminals is not essential and can be omitted.
  • the main terminals 7 and control terminals 6 are part of the lead frame 3, and are connected to the semiconductor chip 1 inside the molded portion 8 by wiring members (not shown) such as aluminum wire.
  • the wiring members do not necessarily have to be aluminum wires, and may be electrically connected by metal wires such as copper wires, or metal plates using joining members such as solder.
  • the main terminals 7 and control terminals 6 are integrated by molding while being exposed from the molded portion 8.
  • the multiple (four) main terminals 7 extend in the left-right direction (first direction) that is parallel to the base portion 14 of the heat sink 16, and are exposed from the molded portion 8. Specifically, two of the main terminals 7 are formed in a straight line extending leftward from the left end of the molded portion 8, and the remaining two main terminals 7 are formed in a straight line extending rightward from the right end of the molded portion 8.
  • the lower surface (second main surface) of the main terminals 7 faces the heat sink 16, and the upper surface (first main surface) of the main terminals 7 faces upward (the side opposite the heat sink 16).
  • the thickness of the lead frame 3 including the main terminals 7 and control terminals 6 is often increased from the viewpoint of current density. For this reason, when attempting to bend a thick lead frame 3 by terminal formation processing, the press tonnage increases, raising concerns about the need for larger equipment and reduced productivity.
  • the lower surface (second main surface) of the main terminal 7 faces the heat sink 16, and the upper surface (first main surface) of the main terminal 7 faces upward (the side opposite the heat sink 16).
  • the main terminal 7, which has a large terminal cross-sectional area is formed to extend horizontally relative to the molded portion 8, eliminating the need for terminal formation processing on the upper and lower surfaces of the main terminal 7. Only the control terminal 6, which has a small terminal cross-sectional area, is subjected to terminal formation processing as necessary, eliminating the need for larger facilities and improving productivity.
  • the terminal forming process of the main terminal 7 is not required, there is no need to increase the length of the main terminal 7 for terminal formation, and it can be shortened.
  • the area of the lead frame 3 including the main terminal 7 can be reduced by the amount of the shortened length of the main terminal 7. This makes it possible to extract multiple shapes from one lead frame (multiple pieces), improving productivity.
  • the area of the lead frame 3 in the power module 202 can be increased while keeping the area of the lead frame 3 including the main terminal 7 the same by the amount of the shortened length of the main terminal 7. This allows for greater freedom in designing the arrangement of the semiconductor chip 1 and the electrical wiring, and improves heat dissipation.
  • FIGS. 3(a) and (b) are top views of a power module 202 according to a modification of the first embodiment.
  • the main terminal 7 may be L-shaped when viewed from above, and as shown in FIG. 3(b), the main terminal 7 may be U-shaped when viewed from above.
  • the shape of the main terminal 7 is not limited to this and can be freely designed. By using such a shape, it is possible to reduce the stress applied to the interface between the main terminal 7 and the molded portion 8 when the main terminal 7 is connected to the bus bar 10. Furthermore, it is also possible to reduce the stress applied to the interface between the main terminal 7 and the molded portion 8 when vibrations occur during use of the product, thereby improving the vibration resistance of the product.
  • FIG. 4 is a cross-sectional view showing the connection between the main terminal 7 and the bus bar 10 provided in the power module 202 according to a modified example of the first embodiment.
  • the main terminal 7 may be crank-shaped in cross-section.
  • the main terminal 7 has a first parallel portion 7a exposed from the molded portion 8 in a first direction parallel to the base portion 14 of the heat sink 16, a first vertical portion 7b extending from the first parallel portion 7a in a second direction vertical to the first parallel portion 7a, and a second parallel portion 7c extending from the first vertical portion 7b in the first direction.
  • the bus bar 10 is connected to a first main surface of the second parallel portion 7c of the main terminal 7.
  • the bent portion has an elastic function, so that it is possible to reduce the stress applied to the interface between the main terminal 7 and the molded portion 8 when the main terminal 7 is connected to the busbar 10. Similarly, it is also possible to reduce the stress applied to the interface between the main terminal 7 and the molded portion 8 when vibrations occur during use of the product, improving the vibration resistance of the product.
  • the shape of the main terminal 7 shown in Figure 4 requires bending, the second parallel portion 7c extends horizontally, so that it is possible to stably connect, for example, one large-area busbar 10 to two main terminals 7.
  • the power module 202 according to the first embodiment has a structure in which the main terminals 7 are arranged on two sides of the molded section 8 when viewed from above, and the control terminals 6 are arranged on the other two sides.
  • the arrangement of the main terminals 7 and the control terminals 6 is not limited to this.
  • FIGS. 5 and 6 are top views of the power module 202 according to a modified example of the first embodiment. As shown in FIG. 5, the main terminals 7 may be arranged on one side, and the control terminals 6 may be arranged on the other two sides, or as shown in FIG. 6, the main terminals 7 and the control terminals 6 may be arranged mixedly on one side, and the design can be freely performed. In this way, by arranging the main terminals 7 and the control terminals 6 on multiple sides of the power module 202, there is an advantage in that the design freedom of the electrical wiring (e.g., aluminum wire) within the power module 202 is increased.
  • the design freedom of the electrical wiring e.g., aluminum wire
  • FIG. 7 is a cross-sectional view showing the bolted connection between the main terminal 7 and busbar 10 of the power module 202 according to the first embodiment.
  • FIG. 8 is a top view showing the bolted connection between the main terminal 7 and busbar 10 of the power module 202 according to the first embodiment.
  • FIG. 9 is a cross-sectional view showing the clearance 18 between the main terminal 7 and terminal block 13 of the power module 202 according to the first embodiment.
  • FIG. 10 is a cross-sectional view showing the bolted connection between the main terminal 7 and busbar 10 when the clearance 18 exists between the main terminal 7 and terminal block 13 of the power module 202 according to the first embodiment.
  • a recess 17 is formed in the upper portion of each terminal block 13 (the main terminal 7 side of each terminal block 13) in which the head of a nut 12 or bolt 11 can be placed.
  • the recess 17 has a first recess 17a and a second recess 17b.
  • the first recess 17a constitutes the upper portion of the recess 17.
  • the second recess 17b is formed below the first recess 17a (towards the heat sink 16) and constitutes the lower portion of the recess 17.
  • the first recess 17a and the second recess 17b are connected, and the outline of the first recess 17a is larger than that of the second recess 17b when viewed from above (the main terminal 7 side).
  • the first recess 17a is formed to a size that allows the heads of the nut 12 and bolt 11 to be placed therein.
  • the second recess 17b is formed to a size that allows the shaft of the bolt 11 that screws into the nut 12 placed in the first recess 17a to be accommodated.
  • the inner surface of the first recess 17a is provided with a rotation suppression portion that suppresses rotation of the head of the nut 12 or bolt 11 placed in the first recess 17a.
  • a cut hole 7d is provided in the main terminal 7, and a cut hole 10a is provided in the bus bar 10 at a location corresponding to the cut hole 7d.
  • the main terminal 7 and the busbar 10 are connected by bolt fastening, the main terminal 7 is displaced until the bolt 11 contacts the nut 12, but once the bolt 11 contacts the nut 12, the displacement of the main terminal 7 does not change any more, and the nut 12 moves toward the main terminal 7.
  • the displacement applied to the main terminal 7 when the main terminal 7 and the busbar 10 are connected by bolt fastening is limited to the clearance 18 between the bolt 11 and the nut 12, not the clearance 18 between the main terminal 7 and the terminal block 13. Therefore, in the first embodiment, the stress applied to the interface between the molded portion 8 and the main terminal 7 is reduced, and the main terminal 7 and the busbar 10 can be connected with good productivity.
  • FIG. 11, FIG. 12(a), (b), and FIG. 13 are cross-sectional views showing the bolt-fastened connection between the main terminal 7 and the bus bar 10 of the power module 202 according to a modified example of the first embodiment.
  • the busbar 10 may be placed above the main terminal 7 (opposite the heat sink 16), with the bolts 11 placed above the busbar 10 and the terminal block 13 and nuts 12 placed below the main terminal 7 (the heat sink 16 side), and the connection may be made by fastening the bolts.
  • the busbar 10 may be placed below the main terminal 7, with the bolts 11 placed above the main terminal 7, and the terminal block 13 and nuts 12 placed below the busbar 10, and the connection may be made by fastening the bolts.
  • the second recess 17b of the terminal block 13 functions as an escape for the bolt 11.
  • the second recess 17b functioning as an escape for the bolt 11 is not necessary, and only the first recess 17a needs to be provided.
  • the second recess 17b is not necessary when the head of the bolt 11 is placed in the recess 17 of the terminal block 13.
  • Figure 14 is a top view of the terminal block 13 and nut 12 provided in the power module 202 according to the first embodiment.
  • Figures 15 to 18 are top views of the terminal block 13 and nut 12 provided in the power module 202 according to a variation of the first embodiment.
  • the terminal block 13 is provided with a recess 17 (specifically, a first recess 17a) that is hexagonal in top view (viewed from the main terminal 7 side).
  • a nut 12 that is hexagonal in top view is disposed in the recess 17.
  • the nut 12 is prevented from rotating and can move toward the main terminal 7 side and the heat sink 16 side.
  • the minimum width of the recess 17 must be smaller than the maximum width of the nut 12.
  • the minimum width of the recess 17 is the minimum distance between the opposing sides of the hexagonal recess 17, i.e., the diameter of the inscribed circle in the hexagonal recess 17.
  • the maximum width of the nut 12 is the maximum distance between the opposing corners of the hexagonal nut 12, i.e., the diameter of the circumscribed circle in the hexagonal nut 12.
  • the minimum width of the recess 17 must be smaller than the maximum width of the head of the bolt 11 in order to prevent the bolt 11 from rotating.
  • the rotation suppression portion that suppresses the rotation of the nut 12 or the head of the bolt 11 placed in the recess 17 is configured based on the relationship between the minimum width of the recess 17 and the maximum width of the head of the nut 12 and bolt 11.
  • the structure of the terminal block 13 and the nut 12 is not limited to the structure shown in FIG. 14.
  • at least one protrusion 19 protruding inward may be formed on the inner surface of the recess 17.
  • the fastening torque of the bolt 11 when connecting the busbar breaks at least one protrusion 19, and the rotation suppression effect of the nut 12 is lost, so that the nut 12 can move to the main terminal 7 side and the heat sink 16 side.
  • the nut 12 is placed in the recess 17 of the terminal block 13 when the terminal block 13 is manufactured, and the terminal block 13 can be transported without the nut 12 falling off, eliminating the need to place the nut 12 on the terminal block 13 when assembling the power module 202, improving productivity.
  • the shape of the protrusion 19 does not have to be round as shown in Figs. 15 and 16, and may be any shape, such as a square or a triangle.
  • the recess 17 may be made to interfere with the nut 12, and the nut 12 may be pressed into it.
  • the nut 12 will not fall off due to vibrations during transportation, and the pressed nut 12 can move to the main terminal 7 side by the fastening torque of the bolt 11 when connecting the busbar, by removing it from the recess 17 of the terminal block 13.
  • the entire recess 17 may interfere with the nut 12 as shown in Fig. 17, or only a part of the recess 17 may interfere with the nut 12 as shown in Figs. 18(a), (b), and (c).
  • FIG. 19 is a cross-sectional view showing the connection by bolt fastening between the terminal block 13 and the heat sink 16 of the power module 202 according to the first embodiment.
  • FIG. 20 is a top view showing the connection by bolt fastening between the terminal block 13 and the heat sink 16 of the power module 202 according to the first embodiment.
  • FIG. 21 is a cross-sectional view showing the connection by solder 2 between the terminal block 13 and the heat sink 16 of the power module 202 according to a modification of the first embodiment.
  • FIG. 22 is a cross-sectional view showing the connection by welding between the terminal block 13 and the heat sink 16 of the power module 202 according to a modification of the first embodiment.
  • FIG. 23 is a cross-sectional view showing the connection by crimping between the terminal block 13 and the heat sink 16 of the power module 202 according to a modification of the first embodiment.
  • the terminal block 13 and the base portion 14 of the heat sink 16 may be connected by any method, such as bolt fastening as shown in Figures 19 and 20, connection using a joining material such as solder 2 as shown in Figure 21, connection by welding as shown in Figure 22, or connection by crimping as shown in Figure 23.
  • reference numeral 20 in Figure 22 indicates a welded portion
  • reference numeral 20a in Figure 23 indicates a crimped portion.
  • the terminal block 13 is connected to the base portion 14 of the heat sink 16, but this is not limited thereto.
  • a positioning groove 22a may be provided in the base portion 14 of the heat sink 16, and a convex positioning portion 22 that can fit into the groove 22a may be provided on the terminal block 13, and the terminal block 13 may be fixed to the base portion 14 of the heat sink 16. In this way, the attachment process of the terminal block 13 can be simplified and productivity can be improved.
  • Figures 25(a) and (b) are cross-sectional views showing the arrangement of terminal block 13 having a positioning structure provided in power module 202 according to a modification of embodiment 1
  • Figure 25(c) is a side view
  • Figures 25(d) and (e) are top views showing the arrangement of terminal block 13 having a positioning structure provided in power module 202 according to a modification of embodiment 1.
  • the positioning portion of the terminal block 13 is not limited to the structure shown in FIG. 24, and may have any structure as long as it can determine the position of the terminal block 13 in at least one direction, for example, as shown in FIG. 25(a) to (e).
  • a positioning groove 22a may be provided on the terminal block 13, and a T-shaped positioning portion 22 may be provided on the base portion 14 in a cross-sectional view.
  • the entire lower end of the terminal block 13 may be used as the positioning portion, and a groove 22a into which the positioning portion can be fitted may be provided on the base portion 14.
  • FIG. 25(a) the entire lower end of the terminal block 13 may be used as the positioning portion, and a groove 22a into which the positioning portion can be fitted may be provided on the base portion 14.
  • two convex positioning portions 22 may be provided on the base portion 14, and two grooves 22a may be provided on the terminal block 13.
  • the positioning portion 22 provided on the base portion 14 may have a shape of two crosses connected together when viewed from above.
  • the two positioning portions 22 provided on the base portion 14 may both be cylindrical. Note that it is also possible to fix the terminal block 13 to the heat sink 16 by combining multiple methods, such as bolt fastening, with the terminal block 13 positioned by the positioning portions 22.
  • FIGS. 26 to 28 are cross-sectional views of a power module 202 according to a modified example of the first embodiment.
  • FIG. 1 shows an example in which a crimped heat sink is used as the heat sink 16, in which a base portion 14 and multiple heat dissipation fins 15 are integrated by crimping.
  • the base portion 14 is processed by machining, die casting, forging, extrusion, or the like, and is made of aluminum or an aluminum alloy.
  • the heat dissipation fins 15 are made of a plate material such as aluminum or an aluminum alloy, which makes it possible to achieve both workability and heat dissipation.
  • the materials of the base 14 and the heat dissipation fins 15 are not limited to aluminum materials, and may be a combination of different materials.
  • the heat dissipation capacity is improved more than that of aluminum-based materials.
  • the heat sink 16 is not limited to the crimped heat sink shown in FIG. 1, and may be an extruded heat sink made by extrusion processing as shown in FIG. 26, a machined heat sink made by cutting processing, or a forged heat sink made by forging, or it may be a die-cast heat sink made by die-cast processing as shown in FIG. 27.
  • the lower surface (other surface) of the module base 5 is provided with a mating portion 5a
  • the upper surface (the surface facing the module base 5) of the base portion 14 of the heat sink 16 is provided with a mated portion 14a that can be mated with the mating portion 5a, and the module base 5 and the heat sink 16 are integrated by mating the mating portion 5a with the mated portion 14a. Therefore, the integration of the module base 5 and the heat sink 16 can be performed in a room temperature process, and the equipment for integration does not become large and complicated, improving productivity.
  • the module base 5 and heat sink 16 may be integrated with a bonding material such as solder 2. It is also possible to integrate the module base 5 and heat sink 16 by combining a number of methods, such as using crimping and a bonding material.
  • the module base 5 is processed by machining, die casting, forging, extrusion, or the like, and is made of aluminum or an aluminum alloy.
  • the material of the module base 5 is not limited to aluminum material, and by using a copper-based plate material, which has a higher thermal conductivity than aluminum-based materials, the heat dissipation capacity is further improved compared to aluminum-based materials.
  • the semiconductor chip 1 may be made of silicon or a wide bandgap semiconductor such as silicon carbide or gallium nitride.
  • the lead frame 3 and bus bar 10 are preferably made of copper-based or aluminum-based materials in terms of electrical resistivity and workability, but this is not limited to the case as long as the material is a metal.
  • the terminal block 13 is made of resin from the viewpoint of workability and insulation. However, the terminal block 13 does not necessarily have to be made of resin, and may be made of a metal material. If it is necessary to ensure the insulation distance between the lead frame 3 and the heat sink 16, and between the lead frame 3 and the nut 12, the terminal block 13 may be made of a composite material in which a metal material is covered with a resin material.
  • the power module 202 includes the semiconductor chip 1, the lead frame 3 having the semiconductor chip 1 mounted on one side thereof, the module base 5 having the lead frame 3 arranged on one side thereof, the main terminals 7 which are part of the lead frame 3, the molded portion 8 which seals the semiconductor chip 1, the lead frame 3, and the module base 5 so that the main terminals 7 are exposed, the base portion 14 which is integrated with the other side of the module base 5 exposed from the molded portion 8, the heat sink 16 which has a plurality of heat dissipation fins 15 which protrude from the base portion 14 on the side opposite to the module base 5, the bus bar 10 which is connected by the bolts 11 and the nuts 12 to the first main surface of the main terminals 7 or the second main surface opposite to the first main surface, and the terminal block 13 which is fixed to the base portion 14 of the heat sink 16 and which is arranged between the main terminals 7 or the bus bar 10 and the base portion 14.
  • a recess 17 is formed on the main terminal 7 side of the terminal block 13, in which the head of a nut 12 or a bolt 11 can be placed, and on the opposite side of the terminal block 13 with respect to the bus bar 10, a bolt 11 that screws into the nut 12 placed in the recess 17, or a nut 12 that screws into the bolt 11 placed in the recess 17, is placed, and a rotation suppression portion is provided on the inner surface of the recess 17 to suppress rotation of the head of the nut 12 or bolt 11 placed in the recess 17.
  • the recess 17, the nut 12, and the head of the bolt 11 are formed in a hexagonal shape when viewed from the main terminal 7 side, the minimum width of the recess 17 is smaller than the maximum width of the head of the nut 12 and the bolt 11, and the rotation suppression portion is configured based on the relationship between the minimum width of the recess 17 and the maximum width of the head of the nut 12 and the bolt 11.
  • the method for manufacturing the power module 202 also includes a step (a) of arranging the head of a nut 12 or bolt 11 in the recess 17 with the busbar 10 placed on the first or second main surface of the main terminal 7, and arranging a bolt 11 that screws into the nut 12 placed in the recess 17, or a nut 12 that screws into the bolt 11 placed in the recess 17, on the opposite side of the busbar 10 from the terminal block 13, and a step (b) of connecting the busbar 10 to the main terminal 7 by rotating the bolt 11 or nut 12 placed on the opposite side of the busbar 10 from the terminal block 13 to screw into the nut 12 or bolt 11 placed in the recess 17.
  • the main terminal 7 is displaced until the bolt 11 or nut 12 arranged on the opposite side of the terminal block 13 with respect to the busbar 10 contacts the nut 12 or bolt 11 arranged on the recess 17, but when the bolt 11 or nut 12 arranged on the opposite side of the terminal block 13 with respect to the busbar 10 contacts the nut 12 or bolt 11 arranged on the recess 17, the main terminal 7 does not displace any further, and the nut 12 or bolt 11 arranged on the recess 17 moves toward the main terminal 7.
  • the displacement applied to the main terminal 7 when the main terminal 7 and the busbar 10 are connected using the bolt 11 and nut 12 is limited to the clearance 18 between the bolt 11 and the nut 12.
  • the recess 17 has a first recess 17a and a second recess 17b formed closer to the heat sink 16 than the first recess 17a, the first recess 17a and the second recess 17b are connected, and the first recess 17a has a larger outline than the second recess 17b when viewed from the main terminal 7 side.
  • the second recess 17b which has a smaller outer size than the first recess 17a, functions as a clearance for the shaft of the bolt 11, allowing the main terminal 7 and busbar 10 to be connected easily and with good productivity.
  • the main terminal 7 also extends in a first direction parallel to the base portion 14 of the heat sink 16 and is exposed from the molded portion 8.
  • terminal forming processing of the main terminals 7 is no longer necessary, improving productivity.
  • the main terminals 7 can be shortened.
  • the area of the lead frame 3 including the main terminals 7 can be reduced by the amount corresponding to the shortened length of the main terminals 7.
  • the area of the lead frame 3 including the main terminals 7 can be increased in the power module 202 while keeping the area of the lead frame 3 including the main terminals 7 the same by the amount corresponding to the shortened length of the main terminals 7.
  • the main terminal 7 has a first parallel portion 7a exposed from the molded portion 8 in a first direction parallel to the base portion 14 of the heat sink 16, a first vertical portion 7b extending from the first parallel portion 7a in a second direction vertical to the first parallel portion 7a, and a second parallel portion 7c extending from the first vertical portion 7b in the first direction, and the bus bar 10 is connected to the second parallel portion 7c of the main terminal 7.
  • At least one protrusion 19 is formed on the inner surface of the recess 17. Therefore, the nut 12 is placed in the recess 17 of the terminal block 13 when the terminal block 13 is manufactured, and the terminal block 13 can be transported without the nut 12 falling off, eliminating the need to place the nut 12 in the recess 17 of the terminal block 13 when assembling the power module 202, improving productivity.
  • a mating portion 5a is provided on the other side of the module base 5, and a mated portion 14a that can be mated with the mating portion 5a is provided on the surface of the base portion 14 of the heat sink 16 facing the module base 5, and the module base 5 and the heat sink 16 are integrated by mating the mating portion 5a with the mated portion 14a.
  • FIG. 29 is a cross-sectional view of the power module 202 according to the second embodiment.
  • FIG. 30 is a cross-sectional view showing a connection by bolt fastening between the main terminal 7 and the bus bar 10 included in the power module 202 according to the second embodiment.
  • FIG. 31 is a top view of the terminal block 13, the nut 12, and the nut dropout prevention member 25 included in the power module 202 according to the second embodiment.
  • FIG. 32 is a cross-sectional view showing a connection by bolt fastening between the main terminal 7 and the bus bar 10 included in the power module 202 according to the modified example of the second embodiment.
  • the same components as those described in the first embodiment are denoted by the same reference numerals, and the description thereof will be omitted.
  • the power module 202 further includes a nut fall prevention member 25 (second structural member) in comparison with the first embodiment.
  • the nut fall-off prevention member 25 is formed in a U-shape in cross section and is attached so that it will not fall off in either direction while being movable toward the main terminal 7 side and the heat sink 16 side relative to the terminal block 13.
  • the nut fall-off prevention member 25 is disposed between the main terminal 7 and the nut 12, and is attached by a fitting below the recess 17 inside the terminal block 13 (towards the heat sink 16). Both ends of the U-shape of the nut fall-off prevention member 25 face inward so as to face each other, and fit into the internal space 13b provided below the recess 17 inside the terminal block 13.
  • the range within which the nut fall-off prevention member 25 can move towards the main terminal 7 needs to be within a range within which the nut 12 does not fall off.
  • the material of the nut fall-prevention member 25 may be any material, such as resin or metal.
  • the nut fall-prevention member 25 is not limited to the structure shown in FIG. 30.
  • the U-shaped ends of the nut fall-prevention member 25 may face outward and upward so that they face in opposite directions. In this way, any structure is acceptable as long as the nut fall-prevention member 25 and the nut 12 do not fall off the terminal block 13 and the nut fall-prevention member 25 and the nut 12 can move to the main terminal 7 side and the heat sink 16 side.
  • the bus bar 10 is connected to the first main surface of the main terminal 7 by the bolt 11 and the nut 12, and the power module 202 is disposed between the main terminal 7 and the nut 12 and further includes a nut fall prevention member 25 attached to the heat sink 16 side of the recess 17 inside the terminal block 13.
  • the method for manufacturing the power module 202 also includes a step (a) of arranging a bolt 11 on the opposite side of the busbar 10 from the terminal block 13 to screw into a nut 12 previously placed in the recess 17, with the busbar 10 placed on the first main surface of the main terminal 7, and a step (b) of connecting the busbar 10 to the main terminal 7 by rotating the bolt 11 placed on the opposite side of the busbar 10 from the terminal block 13 to screw into the nut 12 placed in the recess 17.
  • the nut fall-off prevention member 25 allows the terminal block 13 to be transported without the nut 12 falling off, eliminating the need to place the nut 12 on the terminal block 13 when assembling the power module 202, improving productivity.
  • FIG. 33 is a cross-sectional view of the power module 202 according to the third embodiment.
  • FIG. 34 is a cross-sectional view showing a state before the main terminal 7 and the bus bar 10 included in the power module 202 according to the third embodiment are fastened with a bolt.
  • FIG. 35 is a cross-sectional view showing the connection by fastening the main terminal 7 and the bus bar 10 included in the power module 202 according to the third embodiment by bolt fastening.
  • FIG. 36 is a top view of the terminal block 13, the nut 12, and the nut dropout prevention member 26 included in the power module 202 according to the third embodiment.
  • FIG. 33 is a cross-sectional view of the power module 202 according to the third embodiment.
  • FIG. 34 is a cross-sectional view showing a state before the main terminal 7 and the bus bar 10 included in the power module 202 according to the third embodiment are fastened with a bolt.
  • FIG. 35 is a cross-sectional view showing the connection by fastening the main terminal 7
  • FIG. 37 is a cross-sectional view showing a state before the main terminal 7 and the bus bar 10 included in the power module 202 according to the modified example of the third embodiment are fastened with a bolt.
  • FIG. 38 is a cross-sectional view showing a state before the main terminal 7 and the bus bar 10 included in the power module 202 according to the modified example of the third embodiment are fastened with a bolt.
  • the same components as those described in the first and second embodiments are denoted by the same reference numerals, and the description thereof will be omitted.
  • the power module 202 further includes a nut fall prevention member 26 (second structural member) in comparison with the first embodiment.
  • the nut fall-prevention member 26 is formed in an L-shape in cross section and is fixed to the terminal block 13.
  • the nut fall-prevention member 26 has less rigidity and is flexible compared to the main terminal 7.
  • the nut fall-prevention member 26 may be made of any metal as long as it is flexible.
  • One end of the nut fall-prevention member 26 is disposed between the main terminal 7 and the nut 12, and the other end of the nut fall-prevention member 26 is fixed below the recess 17 inside the terminal block 13 (towards the heat sink 16).
  • the nuts 12 can be placed when the terminal block 13 is manufactured and transported without falling off, eliminating the need to place the nuts 12 on the terminal block 13 when assembling the power module 202, improving productivity. Also, when the bolts are fastened, as shown in FIG. 35, the flexible nut fall-prevention member 26 deforms and the nuts 12 move toward the main terminal 7. The nut fall-prevention member 26 fixed to the terminal block 13 is fastened with the bus bar 10 and the main terminal 7 by the bolts, improving the vibration resistance of the assembled product.
  • the nut fall-prevention member 26 may be fixed to the terminal block 13 by any method, such as insert-molding the nut fall-prevention member 26 when molding the terminal block 13, pressing the nut fall-prevention member 26 after molding the terminal block 13, fixing the nut fall-prevention member 26 to the terminal block 13 using a bolt, or joining the nut fall-prevention member 26 to the terminal block 13 using a bonding material.
  • the nut fall-off prevention member 26 is not limited to the structure shown in Figures 34 and 35, i.e., a structure that covers the outer surface of the nut 12, but may be a structure that covers other surfaces of the side of the nut 12, or a structure that is fixed to the outer surface of the terminal block 13, as shown in Figure 37.
  • a U-shaped portion 27 may be provided at the bent portion of the nut fall-prevention member 26, and the shape of the nut fall-prevention member 26 can be freely designed.
  • the nut fall-prevention member 26 is fixed to the terminal block 13 at one point, but if the nut fall-prevention member 26 itself stretches or is provided with a deforming portion such as a U-shaped structure, so that the nut fall-prevention member 26 can deform toward the main terminal 7, the nut fall-prevention member 26 may be fixed to the terminal block 13 at two points.
  • the busbar 10 is connected to the first main surface of the main terminal 7 by the bolt 11 and the nut 12, and the power module 202 is disposed between the main terminal 7 and the nut 12 and further includes a nut fall prevention member 26 attached to the heat sink 16 side of the recess 17 inside the terminal block 13.
  • the method for manufacturing the power module 202 also includes a step (a) of arranging a bolt 11 on the opposite side of the busbar 10 from the terminal block 13 to screw into a nut 12 previously placed in the recess 17, with the busbar 10 placed on the first main surface of the main terminal 7, and a step (b) of connecting the busbar 10 to the main terminal 7 by rotating the bolt 11 placed on the opposite side of the busbar 10 from the terminal block 13 to screw into the nut 12 placed in the recess 17.
  • the nut fall-off prevention member 26 allows the terminal block 13 to be transported without the nut 12 falling off, eliminating the need to place the nut 12 on the terminal block 13 when assembling the power module 202, improving productivity.
  • the power module 202 according to the above-mentioned embodiments 1 to 3 is applied to a power conversion device.
  • the application of the power module 202 according to the embodiments 1 to 3 is not limited to a specific power conversion device, a case where the power module 202 according to the embodiments 1 to 3 is applied to a three-phase inverter will be described below as embodiment 4.
  • FIG. 39 is a block diagram showing the configuration of a power conversion system to which the power conversion device according to this embodiment is applied.
  • the power conversion system shown in FIG. 39 is composed of a power source 100, a power conversion device 200, and a load 300.
  • the power source 100 is a DC power source and supplies DC power to the power conversion device 200.
  • the power source 100 can be composed of various things, for example, a DC system, a solar cell, or a storage battery, or it may be composed of a rectifier circuit connected to an AC system or an AC/DC converter.
  • the power source 100 may also be composed of a DC/DC converter that converts the DC power output from the DC system into a specified power.
  • the power conversion device 200 is a three-phase inverter connected between the power source 100 and the load 300, converts the DC power supplied from the power source 100 into AC power, and supplies the AC power to the load 300. As shown in FIG. 39, the power conversion device 200 includes a main conversion circuit 201 that converts the DC power into AC power and outputs it, and a control circuit 203 that outputs a control signal to the main conversion circuit 201 to control the main conversion circuit 201.
  • the load 300 is a three-phase motor that is driven by AC power supplied from the power conversion device 200.
  • the load 300 is not limited to a specific use, but is a motor mounted on various electrical devices, and is used, for example, as a motor for hybrid cars, electric cars, railroad cars, elevators, or air conditioning equipment.
  • the power conversion device 200 will be described in detail below.
  • the main conversion circuit 201 includes a switching element (not shown) and a freewheeling diode (not shown), and the switching element switches to convert the DC power supplied from the power source 100 into AC power, which is then supplied to the load 300.
  • the main conversion circuit 201 is a two-level three-phase full bridge circuit that can be configured with six switching elements and six freewheeling diodes connected in inverse parallel to each switching element.
  • the power module 202 according to any of the above-mentioned embodiments 1 to 3 is applied to at least one of the switching elements and freewheeling diodes of the main conversion circuit 201.
  • the six switching elements are connected in series with two switching elements to form upper and lower arms, and each upper and lower arm forms each phase (U phase, V phase, W phase) of the full bridge circuit.
  • the output terminals of each upper and lower arm i.e., the three output terminals of the main conversion circuit 201, are connected to the load 300.
  • the main conversion circuit 201 also includes a drive circuit (not shown) that drives each switching element, but the drive circuit may be built into the power module 202, or the drive circuit may be provided separately from the power module 202.
  • the drive circuit generates drive signals that drive the switching elements of the main conversion circuit 201 and supplies them to the control electrodes of the switching elements of the main conversion circuit 201. Specifically, in accordance with a control signal from the control circuit 203 (described later), a drive signal that turns the switching element on and a drive signal that turns the switching element off are output to the control electrodes of each switching element.
  • the drive signal When the switching element is to be maintained in the on state, the drive signal is a voltage signal (on signal) that is equal to or higher than the threshold voltage of the switching element, and when the switching element is to be maintained in the off state, the drive signal is a voltage signal (off signal) that is equal to or lower than the threshold voltage of the switching element.
  • the control circuit 203 controls the switching elements of the main conversion circuit 201 so that the desired power is supplied to the load 300. Specifically, it calculates the time (on time) that each switching element of the main conversion circuit 201 should be in the on state based on the power to be supplied to the load 300.
  • the main conversion circuit 201 can be controlled by PWM control, which modulates the on time of the switching elements according to the voltage to be output. Then, it outputs a control command (control signal) to a drive circuit provided in the main conversion circuit 201 so that an on signal is output to the switching element that should be in the on state at each point in time, and an off signal is output to the switching element that should be in the off state.
  • the drive circuit outputs an on signal or an off signal as a drive signal to the control electrode of each switching element according to this control signal.
  • the power modules 202 according to embodiments 1 to 3 are used as the switching elements and free wheel diodes of the main conversion circuit 201, which allows for improved productivity.
  • the power modules 202 according to the first to third embodiments are applied to a two-level three-phase inverter, but the application of the power modules 202 according to the first to third embodiments is not limited to this, and they can be applied to various power conversion devices.
  • a two-level power conversion device is used, but a three-level or multi-level power conversion device may also be used, and when supplying power to a single-phase load, the power modules 202 according to the first to third embodiments may be applied to a single-phase inverter.
  • the power modules 202 according to the first to third embodiments can also be applied to a DC/DC converter or an AC/DC converter.
  • the power conversion device to which the power module 202 according to the first to third embodiments is applied is not limited to the case where the load described above is an electric motor, but can also be used, for example, as a power supply device for an electric discharge machine, a laser processing machine, an induction heating cooker, or a non-contact power supply system, and can also be used as a power conditioner for a solar power generation system, a power storage system, etc.
  • each embodiment can be freely combined, modified, or omitted as appropriate.
  • a semiconductor element A semiconductor element; a frame having the semiconductor element mounted on one surface thereof; a module base having the frame disposed on one surface thereof; A main terminal that is a part of the frame; a mold part that seals the semiconductor element, the frame, and the module base so that the main terminals are exposed; and a heat sink including a base portion integrated with the other surface of the module base exposed from the mold portion, and a plurality of heat dissipation fins protruding from the base portion on a side opposite to the module base; an external terminal connected by a bolt and a nut to a first main surface of the main terminal or a second main surface opposite to the first main surface; a structural member fixed to the base portion of the heat sink and disposed between the main terminal or the external terminal and the base portion, a recess in which a head of the nut or the bolt can be placed is formed on the main terminal side of the structural member, the bolt that screws into the nut disposed in the recess or the nut that screws into the bolt disposed
  • the recess includes a first recess and a second recess formed closer to the heat sink than the first recess, The first recess and the second recess are in communication with each other, The power module according to claim 1, wherein the first recess has a larger contour than the second recess when viewed from the main terminal side.
  • the main terminal has a first parallel portion exposed from the molded portion in a first direction parallel to the base portion of the heat sink, a first vertical portion extending from the first parallel portion in a second direction vertical to the base portion of the heat sink, and a second parallel portion extending from the first vertical portion in the first direction; 3.
  • the recess, the nut, and the head of the bolt are formed in a hexagonal shape when viewed from the main terminal side, a minimum width of the recess is smaller than a maximum width of the head of the nut and the head of the bolt; 5.
  • the power module according to claim 1, wherein the rotation suppressing portion is configured based on a relationship between a minimum width of the recess and a maximum width of the heads of the nuts and the bolts.
  • the external terminal is connected to the first main surface of the main terminal by the bolt and the nut, 7.
  • a fitting portion is provided on the other surface of the module base, a mating portion that can be mated with the mating portion is provided on a surface of the base portion of the heat sink that faces the module base, 9.
  • a power conversion device comprising:

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  • Inverter Devices (AREA)
  • Connections Arranged To Contact A Plurality Of Conductors (AREA)
PCT/JP2024/003469 2023-02-14 2024-02-02 パワーモジュール、パワーモジュールの製造方法、および電力変換装置 Ceased WO2024171848A1 (ja)

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