Source: http://www.docstoc.com/docs/97910452/Power-Converter-Apparatus---Patent-8018730
Timestamp: 2015-07-05 18:37:05
Document Index: 602145132

Matched Legal Cases: ['Application No. 2008', 'Application No. 2008', 'Application No.2008', 'Application No. 2008', 'Application No. 2008', 'Application No.\n2008']

Power Converter Apparatus - Patent 8018730 by Patents-112
97910452
This application claims priority to Japanese Patent Application No. 2008-132267 filed May 20, 2008 which claims priority to Japanese Patent Application No. 2008-129483, filed May 16, 2008, which claims priority to Japanese Patent Application No.2008-054049, filed Mar. 4, 2008.BACKGROUND The present invention relates to a power converter apparatus. Japanese Laid-Open Patent Publication No. 2005-347561 discloses a structure of a power converter apparatus having switching elements and capacitors, in which a portion of the capacitor interconnection member that corresponds to an externalconnection terminal is configured to reduce parasitic inductance of the interconnection. Specifically, as shown in FIGS. 17A and 17B, six insulated substrates 101 are provided on the upper surface of a base 100, and a collector pattern 102 and anemitter pattern 103 are formed on each insulated substrate 101. A switching chip 104 and a diode chip 105 are mounted on the collector pattern 102, and the switching chip 104 and the diode chip 105 are connected to the emitter pattern 103 by bondingwires 106. A P-type conductor 107 includes a plate-like main conductor 107a and three connecting conductors 107b projecting downward from the main conductor 107a. The P-type conductor 107 is connected to the insulated substrates 101 at the connectingconductors 107b. Likewise, an N-type conductor 108 includes a plate-like main conductor 108a and three connecting conductors 108b projecting downward from the main conductor 108a. The N-type conductor 108 is connected to the insulated substrates 101 atthe connecting conductors 108b. The main conductors 107a, 108a are laminated together, while being insulated from each other. Belt-like sub-conductors 107c, 108c are provided at ends of the main conductors 107a, 108a, respectively. The sub-conductors107c, 108c are laminated together, while being insulated from each other. The ends of the sub-conductors 107c, 108c form external connecting terminals P
United States Patent: 8018730
8,018,730
A power converter apparatus includes a substrate 22 on which switching
elements Q, Q1 to Q6 are mounted, positive and negative terminal
interconnection members 27, 28 mounted on the substrate, and a capacitor
17 having a positive terminal 17a connected to the main body of the
positive terminal interconnection member 27 and a negative terminal 17b
connected to the main body of the negative terminal interconnection
member 28. The interconnection members each have a plate-like main body
27a, 28a that is located above and parallel to the substrate 22. The main
bodies of the interconnection members are stacked to be close to each
other while being electrically insulated from each other. Each of the
positive terminal interconnection member and the negative terminal
interconnection member further includes a plate-like extension 27b, 28b
that extends from the corresponding main body toward the substrate, and a
terminal portion 27c, 28c that extends from the extension and is joined
to the substrate. The extensions extend to positions closest to the
substrate, while being parallel to and close to each other.
Onishi; Hiroyuki (Aichi-Ken, JP), Nagase; Toshiaki (Aichi-ken, JP), Ishikawa; Jun (Kariya, JP), Kontani; Kazuyoshi (Kariya, JP), Fukatsu; Toshinari (Kariya, JP), Kobayashi; Hiroyuki (Kariya, JP), Kanie; Naohito (Kariya, JP), Nakamura; Takahiro (Kariya, JP)
12/397,151
2008-054049
2008-129483
2008-132267
361/763  ; 361/611; 361/624; 361/637; 361/782
361/760,781-783,773,774,278,299,298,306.1,622,624,632,637,639,648,750,200
2006/0255448
2007/0051974
2007/0109715
2007/0279864
2010/0155158
11-163257
2000-060126
2002-044964
2004-214452
2005-261035
2006-253516
2006-318953
2007-143272
1.  A power converter apparatus comprising: a substrate on which switching elements are mounted;  a positive terminal interconnection member and a negative terminal
interconnection member placed on the substrate, wherein the interconnection members each have a plate-like main body that is located above and parallel to the substrate, and wherein the main bodies of the interconnection members are stacked to be close
to each other while being electrically insulated from each other;  and a capacitor having a positive terminal connected to the main body of the positive terminal interconnection member and a negative terminal connected to the main body of the negative
terminal interconnection member, wherein each of the positive terminal interconnection member and the negative terminal interconnection member further includes a plate-like extension that extends from the corresponding main body toward the substrate, and
a terminal portion that extends from the extension and is joined to the substrate, the extensions extending to positions closest to the substrate while being parallel to and close to each other.
2.  The power converter apparatus according to claim 1, wherein an insulation member is provided between the main bodies of the interconnection members, and between the extensions of the interconnection members.
3.  The power converter apparatus according to claim 1, wherein a notch for limiting the flow of current is formed in each of the extensions.
4.  The power converter apparatus according to claim 3, wherein the width of the notch is determined to be a value that does not hinder the passage of gel for insulation or protection.
5.  The power converter apparatus according to claim 1, wherein, of the main bodies of the two interconnection members, the capacitor is mounted on the main body that is farther from the substrate.
6.  The power converter apparatus according to claim 1, wherein each extension includes a bent portion, which is shaped like an angle iron in relation to the corresponding main body, and wherein the thickness of the extensions and the thickness
of the terminal portions are less than the thickness of the main bodies.
7.  The power converter apparatus according to claim 6, wherein each interconnection member includes a first surface having a step at a section where the thickness changes, and a second surface on the opposite side to the first surface, wherein
the interconnection members are arranged such that the second surfaces face each other.
8.  The power converter apparatus according to claim 6, wherein each interconnection member includes a first surface having a step at a section where the thickness changes, and a second surface on the opposite side to the first surface, wherein
the interconnection members are arranged such that a first surface and a second surface face each other.
9.  The power converter apparatus according to claim 6, wherein each bent portion is formed in a thin section of the corresponding interconnection member.
10.  The power converter apparatus according to claim 1, wherein the substrate has a circuit pattern on which a plurality of semiconductor chips including the switching elements are mounted, and wherein each terminal portion has at its distal
end a joint portion that is joined to the circuit pattern, wherein the terminal portions are bent such that the cross-sectional shape of each interconnection member is cranked between the main body and the joint portion, and wherein each joint portion is
joined to the circuit pattern, so as to be spaced from the semiconductor chips by equal distances.
11.  The power converter apparatus according to claim 1, wherein the terminal portions are joined to the substrate by ultrasonic bonding.  Description
This application claims priority to Japanese Patent Application No. 2008-132267 filed May 20, 2008 which claims priority to Japanese Patent Application No. 2008-129483, filed May 16, 2008, which claims priority to Japanese Patent Application No.
2008-054049, filed Mar.  4, 2008.
The present invention relates to a power converter apparatus.
Japanese Laid-Open Patent Publication No. 2005-347561 discloses a structure of a power converter apparatus having switching elements and capacitors, in which a portion of the capacitor interconnection member that corresponds to an external
connection terminal is configured to reduce parasitic inductance of the interconnection.  Specifically, as shown in FIGS. 17A and 17B, six insulated substrates 101 are provided on the upper surface of a base 100, and a collector pattern 102 and an
emitter pattern 103 are formed on each insulated substrate 101.  A switching chip 104 and a diode chip 105 are mounted on the collector pattern 102, and the switching chip 104 and the diode chip 105 are connected to the emitter pattern 103 by bonding
wires 106.  A P-type conductor 107 includes a plate-like main conductor 107a and three connecting conductors 107b projecting downward from the main conductor 107a.  The P-type conductor 107 is connected to the insulated substrates 101 at the connecting
conductors 107b.  Likewise, an N-type conductor 108 includes a plate-like main conductor 108a and three connecting conductors 108b projecting downward from the main conductor 108a.  The N-type conductor 108 is connected to the insulated substrates 101 at
the connecting conductors 108b.  The main conductors 107a, 108a are laminated together, while being insulated from each other.  Belt-like sub-conductors 107c, 108c are provided at ends of the main conductors 107a, 108a, respectively.  The sub-conductors
107c, 108c are laminated together, while being insulated from each other.  The ends of the sub-conductors 107c, 108c form external connecting terminals P10, N10, respectively.
However, to reduce the parasitic inductance in the interconnection of the capacitor, it is not sufficient to provide an improved structure of the external connecting terminals P10, N1 in the capacitor interconnection member.  Specifically,
parasitic inductance in the interconnection needs to be reduced.
Accordingly, it is an objective of the present invention to provide a power converter apparatus that further reduces parasitic inductance of capacitor interconnection.
To achieve the foregoing objective and in accordance with one aspect of the present invention, a power converter apparatus including a substrate, a positive terminal interconnection member, a negative terminal interconnection member, and a
capacitor is provided.  Switching elements are mounted on the substrate.  The positive terminal interconnection member and a negative terminal interconnection member are placed on the substrate.  The interconnection members each have a plate-like main
body that is located above and parallel to the substrate.  The main bodies of the interconnection members are stacked to be close to each other while being electrically insulated from each other.  The capacitor has a positive terminal connected to the
main body of the positive terminal interconnection member and a negative terminal connected to the main body of the negative terminal interconnection member.  Each of the positive terminal interconnection member and the negative terminal interconnection
member further includes a plate-like extension that extends from the corresponding main body toward the substrate, and a terminal portion that extends from the extension and is joined to the substrate.  The extensions extending to positions closest to
the substrate while being parallel to and close to each other.
FIG. 1A is a circuit diagram showing an inverter apparatus, which is a power converter apparatus according to a first embodiment of the present invention;
FIG. 7B is a schematic perspective view illustrating a metal base on which the ceramic substrate of FIG. 7A is mounted;
FIG. 8A is a schematic perspective view showing a state in which a support frame is attached to the metal base of FIG. 7B;
FIG. 8B is a schematic perspective view showing a state in which output electrode members are attached to the metal base of FIG. 8A;
FIG. 9 is a schematic perspective view showing the relationship among the capacitor assembly, the metal base, the support frame, and the output electrode members in the inverter apparatus of FIG. 1A;
FIG. 10 is a schematic perspective view showing the relationship among the capacitor assembly, the metal base, the support frame, and the output electrode members in an inverter apparatus according to a second embodiment of the present
FIG. 11A is a cross-sectional view corresponding to the cross-section taken along line 4A-4A of FIG. 3, showing the inverter apparatus of FIG. 10;
FIG. 11B is a partially enlarged view of FIG. 11A, from which a part is omitted;
FIG. 12 is a cross-sectional view showing an inverter apparatus, which is a power converter apparatus according to another embodiment;
FIG. 13 is a plan view showing an inverter apparatus, which is a power converter apparatus according to a third embodiment of the present invention, from which the cover is omitted;
FIG. 14 is a schematic perspective view showing the relationship among the capacitor assembly, the metal base, the support frame, and the output electrode members in the inverter apparatus of FIG. 13;
FIG. 15A is a cross-sectional view taken along line 15A-15A in FIG. 13;
FIG. 15B is a partially enlarged view of FIG. 15A, from which a part is omitted;
FIG. 16 is a cross-sectional view showing an inverter apparatus, which is a power converter apparatus according to another embodiment;
FIG. 17A is a perspective view illustrating a prior art power converter apparatus; and
FIG. 17B is an exploded perspective view showing the power converter apparatus of FIG. 17A.
A three-phase inverter apparatus 11 according to a first embodiment of the present invention will now be described with reference to FIGS. 1A to 9.
First, the circuit configuration of the inverter apparatus will be described.  As shown in FIG. 1A, the inverter apparatus 11 has an inverter circuit 12 with six switching elements Q1 to Q6.  MOSFETs (metal-oxide-semiconductor field-effect
transistors) are used as the switching elements Q1 to Q6.  In each of the pair of the first and second switching elements Q1, Q2, the pair of the third and fourth switching elements Q3, Q4, and the pair of the fifth and sixth switching elements Q5, Q6,
the switching elements are connected in series.  Diodes D1 to D6 are connected in inverse parallel with a part between the drain and the source of the switching elements Q1 to Q6, respectively.  Each of the switching elements Q1, Q3, Q5 and the
corresponding one of the diodes D1, D3, D5 connected thereto form a structure that is referred to as an upper arm.  Also, each of the switching elements Q2, Q4, Q6 and the corresponding one of the diode D2, D4, D6 connected thereto form a structure that
is referred to as a lower arm.
The drains of the switching elements Q1, Q3, Q5 are connected to a positive input terminal 14 for inputting power through a line 13, and the sources of the switching elements Q2, Q4, Q6 are connected to a negative input terminal 16 for inputting
power through a line 15.  A plurality of capacitors 17 are connected in parallel between the line 13 and the line 15.  In the present embodiment, electrolytic capacitors are used as the capacitors 17.  The positive terminals and the negative terminals of
the capacitors 17 are connected to the line 13 and the line 15, respectively.
The node between the switching elements Q1, Q2 is connected to a U-phase terminal U, the node between the switching elements Q3, Q4 is connected to a V-phase terminal V, and the node between the switching elements Q5, Q6 is connected to a
W-phase terminal W. The gates of the switching elements Q1 to Q6 are connected to drive signal input terminals G1 to G6, respectively.  The sources of the switching elements Q1 to Q6 are connected to signal terminals S1 to S6, respectively.
In FIG. 1A, each of the upper arms and the lower arms includes one switching element and one diode.  However, in a case where the amount of current through each arm is great, each arm may be configured with a plurality of parallel connected
pairs of switching elements Q and diodes D as shown in FIG. 1B.  In the present embodiment, each arm is formed by four pairs of a switching element Q and a diode D.
As shown in FIGS. 2 and 3, the inverter apparatus 11 includes a substrate 22 formed by a metal base 20 made of copper and a plurality of ceramic substrates 21, which are insulated substrates.  Semiconductor chips 23 are mounted on the substrate
22.  Each semiconductor chip 23 incorporates one switching element (MOSFET) and one diode, which form a single device.  That is, each semiconductor chip 23 corresponds to one of the devices provided with a single switching element Q and a single diode D
Each ceramic substrate 21 has a ceramic plate 26, which is formed of, for example, aluminum nitride, alumina, or silicon nitride.  As shown in FIG. 5, circuit patterns 24a, 24b, 24c, 24d are formed on the upper surface of the ceramic plate 26.
As shown in FIG. 4B, a metal plate 25 is provided on the lower surface of the ceramic plate 26.  The circuit patterns 24a, 24b, 24c, 24d and the metal plate 25 are made of, for example, aluminum or copper.  The metal plate 25 functions as a joining layer
that joins the ceramic substrates 21 and the metal base 20 with each other.  The ceramic substrates 21 are joined to the metal base 20 with the metal plates 25 in between using solder (not shown).  Hereinafter, the metal base 20 is referred to a bottom
portion (lower portion) of the inverter apparatus 11.
As shown in FIG. 5, the circuit patterns 24a, 24b, 24c, and 24d are circuit patterns for gate signals, drains, sources, and source signals, respectively.  Each of the circuit patterns 24a to 24d is formed like a belt.  The drain circuit pattern
24b and the source circuit pattern 24c are adjacent to and parallel with each other.  The gate signal circuit pattern 24a and the source signal circuit pattern 24d are located opposite to the circuit pattern 24c and parallel with the circuit pattern 24b. The semiconductor chips 23 are joined to the drain circuit pattern 24b with solder.  The gates of the semiconductor chips 23 and the gate signal circuit pattern 24a are electrically connected to each other by wire bonding.  The sources of the
semiconductor chips 23 are electrically connected to the source circuit patterns 24c and the source signal circuit patterns 24d by wire bonding.
As shown in FIG. 7B, the metal base 20 is substantially rectangular.  Twelve ceramic substrates 21 are provided on the metal base 20 and are arranged in six rows and two columns, such that the longitudinal direction of the ceramic substrates 21
is perpendicular to the longitudinal direction of the metal base 20.  The semiconductor chips 23 on two ceramic substrates 21 on each row form an arm of the inverter circuit 12.  In the present embodiment, two semiconductor chips 23 are mounted on each
ceramic substrate 21, and the four semiconductor chips 23 on the two ceramic substrate 21 in each row form one arm.  As shown in FIG. 5, the two semiconductor chips 23 on each ceramic substrate 21 are arranged at ends in the longitudinal direction of the
circuit pattern 24b, so that a space exists between the semiconductor chips 23.
As shown in FIGS. 3 to 4B, a plate-like positive interconnection member 27 and a plate-like negative interconnection member 28 are located on the substrate 22 in a stacked state.  In the present embodiment, the negative interconnection member 28
is located over the positive interconnection member 27.  The positive interconnection member 27 and the negative interconnection member 28 form the line 13 and the line 15 shown in FIG. 1A, respectively.
As show in FIGS. 4A and 4B, the positive interconnection member 27 and the negative interconnection member 28 include plate-like rectangular main bodies 27a, 28a and a pair of downward extensions 27b, 28b serving as extensions, respectively.
The main bodies 27a, 28a are located above the substrate 22 to be parallel with the substrate 22, and are arranged close to each other while being insulated from each other.  The pairs of the downward extensions 27b, 28b are located at ends of the
corresponding main body 27a, 28a in the widthwise direction while being bent to extend toward the substrate 22.  The downward extensions 27b, 28b in each pair are symmetry with respect to a line passing through the center of the corresponding one of the
main bodies 27a, 28a in the widthwise direction.  In each side of the main bodies 27a, 28a, the downward extension 27b and the downward extension 28b are stacked on each other.  In this manner, in each side of the main bodies 27a, 28a, the downward
extension 27b and the downward extension 28b extend from the main bodies 27a, 28a to the vicinity of the substrate 22 (the ceramic substrate 21) while being close to and parallel to each other.
The positive interconnection member 27 and the negative interconnection member 28 have a plurality of terminal portions 27c, 28c, respectively.  The terminal portions 27c, 28c each extend downward from the lower ends of the downward extensions
27b, 28b, and then bent to extend parallel with the main bodies 27a, 28a (see FIG. 2).  In the present embodiment, three pairs of the terminal portions 27c, 28c, or six terminal portions, are provided.  As shown in FIG. 3, each terminal portion 27c has a
joint portion 27c1 at the distal end.  At the joint portion 27c1, the terminal portion 27c is joined by ultrasonic bonding to a center of the drain circuit pattern 24b on the ceramic substrate 21 having the semiconductor chip 23 forming an upper arm.
Each terminal portion 28c also has a joint portion 28c1 at the distal end.  At the joint portion 28c1, the terminal portion 28c is joined by ultrasonic bonding to a center of the source circuit pattern 24c on the ceramic substrate 21 having the
semiconductor chip 23 forming a lower arm.  The joint portions 27c1, 28c1, which are on the same side of the interconnection members 27, 28 in the widthwise direction, that is, joint portions between the terminal portions 27c, 28c and the circuit
patterns 24b, 24c that are joined by ultrasonic bonding are located on a single straight line.
In FIGS. 6A and 6B, a plurality of notches 27d, 28d are formed in the downward extensions 27b, 28b, respectively.  The notches 27d of the downward extension 27b face the notches 28d of the downward extension 28b.  The notches 27d, 28d function
to limit the flow of current.  That is, the notches 27d, 28d are capable of limiting electric currents i1, i2, i3, which flow into the upper arms through the positive interconnection member 27 shown in FIGS. 1A and 6A, and electric current i4, i5, i6,
which flow out of the lower arms through the negative interconnection member 28.  The widths of the notches 27d, 28d are determined to be a value that does not hinder the passage of gel 36, which will be discussed below (see FIG. 4A).
On the other hand, as shown in FIG. 4B, an insulation sheet 29 is located between the main body 27a of the positive interconnection member 27 and the main body 28a of the negative interconnection member 28.  The insulation sheet 29 functions as
an insulation member that electrically insulates the main bodies 27a, 28a from each other.  Examples of the insulation sheet 29 include a resin sheet.  The main body 27a of the positive interconnection member 27, the main body 28a of the negative
interconnection member 28, and the insulation sheet 29 have elongated holes into which a positive terminal 17a and a negative terminal 17b of a capacitor 17 can be inserted.
As shown in FIGS. 2 and 3, a support frame 30 made of electrical insulation material is fixed to the metal base 20 to extend along the edge of the metal base 20.  All the ceramic substrates 21 are accommodated in the support frame 30.  The
positive input terminal 14 for receiving outer power is formed at a longitudinal end of the main body 27a of the positive interconnection member 27.  The positive input terminal 14 extends outside of the support frame 30.  The negative input terminal 16
is formed at a longitudinal end of the main body 28a of the negative interconnection member 28, specifically, the end opposite to the positive input terminal 14.  The negative input terminal 16 extends outside of the support frame 30.
As shown in FIGS. 4A and 4B, the capacitors 17 are arranged on one of the main body 27a of the positive interconnection member 27 and the main body 28a of the negative interconnection member 28 that is farther from the substrate 22, that is, on
the main body 28a of the negative interconnection member 28.  In the present embodiment, four capacitors 17 are arranged on the main body 28a with electrical insulation member (not shown) in between, such that the positive terminals 17a and the negative
terminals 17b face the substrate 22.  The positive terminal 17a and the negative terminal 17b of each capacitor 17 are located on one side of the capacitor main body.  The positive terminal 17a is connected to the main body 27a of the positive
interconnection member 27, and the negative terminal 17b is connected to the main body 28a of the negative interconnection member 28.
As shown in FIGS. 2 and 3, three output electrode members 32U, 32V, 32W of the inverter apparatus 11 each have a portion that extends upward and a portion that extends laterally, so as to be shaped like L as viewed from the side.  The upward
extending portion is located close to the support frame 30, and the laterally extending portion extends perpendicular to the longitudinal direction of the positive interconnection member 27 below the main body 27a of the positive interconnection member
27.  The insulation between the positive interconnection member 27 and the output electrode members 32U, 32V, 32W is ensured by the gel 36 (shown in FIG. 4A), which is, for example, silicone gel.  The insulation between the downward extension 27b of the
positive interconnection member 27 and the downward extension 28b of the negative interconnection member 28 is also ensured by the gel 36.  The gel 36 is accommodated in the space encompassed by the support frame 30.
As shown in, for example, FIG. 3, the output electrode members 32U, 32V, 32W are each formed by pressing a copper plate the width of which is substantially equal to the width of the ceramic substrates 21.  As shown in FIG. 5, each of the output
electrode members 32U, 32V, 32W has four joint portions 35.  Two of the joint portions 35 are joined to substantially centers of the circuit patterns 24c of the two ceramic substrate 21 having the semiconductor chips 23 that form the upper arm.  The
other two are joined to substantially centers of the circuit patterns 24b of the two ceramic substrate 21 having the semiconductor chips 23 that form the lower arm.  More specifically, the output electrode member 32U is joined by ultrasonic bonding to
the source circuit pattern 24c of the upper arm formed by the first switching element Q1 and the diode D1, and to the drain circuit pattern 24b of the lower arm formed by the second switching element Q2 and the diode D2.  The output electrode member 32V
is joined by ultrasonic bonding to the source circuit pattern 24c of the upper arm formed by the third switching element Q3 and the diode D3, and to the drain circuit pattern 24b of the lower arm formed by the fourth switching element Q4 and the diode
D4.  The output electrode member 32W is joined by ultrasonic bonding to the source circuit pattern 24c of the upper arm formed by the fifth switching element Q5 and the diode D5, and to the drain circuit pattern 24b of the lower arm formed by the sixth
switching element Q6 and the diode D6.
As shown in FIG. 8B, each of the substantially L-shaped output electrode members 32U, 32V, 32W has a horizontal portion, which has a pair of the joint portions 35 at the proximal end (a part closer to the bent portion), and another pair of the
joint portions 35 at the distal end.  The joint portions 35 extend toward the substrate 22 from the horizontal portion.  A space 50 capable of receiving the terminal portion 28c of the negative interconnection member 28 is defined between the joint
portions 35 at the proximal side and between the joint portions 35 at the distal side.  As shown in FIG. 3, a pair of the joint portions 35 and the joint portions 27c1, 28c1 are arranged on a single line at each of the widthwise sides of the
interconnection members 27, 28.
As shown in FIGS. 3 and 5, of the two ceramic substrates 21 corresponding to each arm, the gate signal circuit patterns 24a and the source signal circuit patterns 24d of the ceramic substrate 21 located at the distal end of the horizontal
portion of the output electrode members 32U, 32V, 32W are connected to the drive signal input terminals G1 to G6 and the signal terminals S1 to S6, respectively.  The terminals G1 to G6 and S1 to S6 are integrally molded with the support frame 30 so as
to extend through the support frame 30, so that second ends project from the support frame 30.  In FIG. 5, the circuit patterns 24a formed on the two ceramic substrates 21 of each arm are electrically connected to each other by wire bonding.  Also, the
circuit patterns 24d formed on the two ceramic substrates 21 of each arm are electrically connected to each other by wire bonding.
As shown in FIG. 4A, the support frame 30 is filled with the gel 36, which is then cured to insulate and protect the semiconductor chips 23.  A cover 37 may be fixed to the metal base 20 with bolts to cover the surface of the substrate 22 on
which the semiconductor chips 23, or the switching elements Q1 to Q6 are mounted, the positive interconnection member 27, the negative interconnection member 28, the capacitors 17, the output electrode members 32U, 32V, 32W, the support frame 30.
First, a step for mounting the semiconductor chips 23 on the ceramic substrates 21 will be described.  In this step, as shown in FIG. 7A, two semiconductor chips 23 are joined by soldering to the drain circuit pattern 24b on a ceramic substrate
21 such that a space exists in a center in the longitudinal direction.  As shown in FIG. 5, the gate of each semiconductor chip 23 and the gate signal circuit pattern 24a are connected to each other by wire bonding, the source of each semiconductor chip
23 and the source circuit pattern 24c are connected to each other by wire bonding, and the source of each semiconductor chip 23 and the source signal circuit pattern 24d are connected to each other by wire bonding.
Next, a step for joining ceramic substrate 21 to the metal base 20 will be described.  In this step, as shown in FIG. 7B, the ceramic substrates 21 on which the semiconductor chips 23 are mounted are joined by soldering to the metal base 20 in
six rows and two columns.  As shown in FIG. 5, the circuit pattern 24a and the circuit pattern 24d of each ceramic substrates 21 having the arms are electrically connected to the circuit pattern 24a and the circuit pattern 24d of another ceramic
substrate 21 having the arms, respectively.
Next, a step for joining output electrode members 32U, 32V, 32W to the ceramic substrates 21 will be described.  In this step, as shown in FIG. 8A, a support frame 30 having drive signal input terminals G1 to G6 and signal terminals S1 to S6 is
fixed to the metal base 20 so as to encompass the ceramic substrates 21.  The support frame 30 is fixed by means of adhesive or screws.  Then, as shown in FIG. 8B, the output electrode members 32U, 32V, 32W are arranged such that each joint portion 35
contacts a substantially center of one of the drain circuit pattern 24b and the source circuit pattern 24c (see FIG. 5).  Subsequently, the joint portions 35 are successively joined by ultrasonic bonding to the circuit patterns 24b and the circuit
patterns 24c.  Also, the first ends of the drive signal input terminals G1 to G6 are joined to the circuit patterns 24a by ultrasonic bonding, and the first ends of the signal terminals S1 to S6 are joined to the circuit patterns 24d by ultrasonic
Then, a step for assembling a capacitor assembly 38 shown in FIG. 9 is performed.  In this step, four capacitors 17 are fixed along a single line at predetermined intervals using a jig, such that the positive terminals 17a and the negative
terminals 17b face upward.  Then, a negative interconnection member 28 is fixed to the negative terminals 17b of the capacitors 17 with insulating material in between.  Subsequently, a positive interconnection member 27 is fixed to the positive terminals
17a of the capacitors 17 while placing an insulation sheet 29 between the positive interconnection member 27 and the main body 28a of the negative interconnection member 28.  In this manner, the capacitor assembly 38 is assembled such that the main body
27a of the positive interconnection member 27 and the main body 28a of the negative interconnection member 28 are insulated from each other, and that the positive interconnection member 27 and the negative interconnection member 28 are electrically
connected to the positive terminals 17a and the negative terminals 17b of the capacitors 17, respectively.
Next, a step for joining by ultrasonic bonding the capacitor assembly 38 to the ceramic substrates 21 will be described.  In this step, the capacitor assembly 38 is first placed on the ceramic substrates 21.  As shown in FIG. 9, the capacitor
assembly 38 is arranged at a predetermined position in the support frame 30 from above the ceramic substrates 21.  At this time, as shown in FIG. 3, the joint portions 27c1, 28c1 on the same side of the interconnection members 27, 28 in the widthwise
direction are located on a single line.
Thereafter, the terminal portions 27c, 28c are successively joined to the circuit patterns 24b, 24c at the joint portions 27c1, 28c1 by ultrasonic bonding.  The joint portions 27c1, 28c1 are close to the capacitors 17.  Thus, if general
capacitors in which the heat resistance is not particularly considered are used as the capacitors 17, and soldering is used to join the terminal portions 27c, 28c, the heat accompanying the soldering can adversely affect the capacitors 17.  However,
since the terminal portions 27c, 28c and the circuit patterns 24b, 24c are joined by ultrasonic bonding, the amount of heat applied to the capacitors 17 is less than the case where soldering is performed.  Thus, special capacitors with enhanced heat
resistance are not required.
As shown in FIG. 4, to electrically insulate and protect portions that should be kept away from moisture and oxidation, for example, the semiconductor chips 23 and joint portions, the support frame 30 is filled with gel 36, which is then cured.
As shown in FIGS. 6A and 6B, the downward extensions 27b, 28b of the positive interconnection member 27 and the negative interconnection member 28 have notches 27d, 28d, respectively.  Compared to the case where no notches 27d, 28d are provided, the gel
36 easily flows into the space between the positive interconnection member 27 and the negative interconnection member 28.  Consequently, the cover 37 is fixed to the metal base 20 with bolts, so that the inverter apparatus 11 is completed as shown in
The inverter apparatus 11 is, for example, a part of the power supply unit of a vehicle.  In the inverter apparatus 11 shown in FIG. 1A, the positive input terminal 14 and the negative input terminal 16 are connected to a DC power source (not
shown), and the U-phase terminal U, the V-phase terminal V, and the W-phase terminal W are connected to a motor (not shown).  The drive signal input terminals G1 to G6 and the signal terminals S1 to S6 are connected to a control unit (not shown).
In FIG. 2, at switching of the switching elements Q1 to Q6, a current that abruptly rises or a current that abruptly falls flows through the positive interconnection member 27 and the negative interconnection member 28.  The flowing directions
of the current in the positive interconnection member 27 and the negative interconnection member 28 are opposite to each other.  Since the flat plate-like main body 27a, 28a are parallel to and close to each other, the inductance of the interconnection
is reduced by the effect of mutual inductance.  The downward extensions 27b, 28b are also parallel to and close to each other, and the directions of the flows of current are opposite to each other.  This further reduces the inductance of the
In this manner, the inductance of the line from the capacitors 17 to a position closest to the semiconductor chips 23 is reduced, and the surge voltage generated when the switching of the switching elements Q1 to Q6 is suppressed.  Therefore,
the semiconductor chips 23 are prevented from being damaged.
Further, the downward extensions 27b, 28b have the notches 27d, 28d for limiting the flow of current.  This prevents the U, V, and W phases from affecting each other.
(1) In the positive interconnection member 27 and the negative interconnection member 28, the pairs of the downward extensions 27b, 28b serving as extensions extend from the main bodies 27a, 28a to positions closest to the substrate 22 while
being parallel to each other.  This reduces the parasitic inductance in the interconnection of the capacitors.
(2) The insulation sheet 29 and the gel 36 serving as insulating members are located between the main body 27a of the positive interconnection member 27 and the main body 28a of the negative interconnection member 28 and between the downward
extension 27b of the positive interconnection member 27 and the downward extension 28b of the negative interconnection member 28.  This configuration is suitable for insulating between the positive interconnection member 27 and the negative
interconnection member 28.
(3) The notches 27d, 28d for limiting the flow of current are formed in the downward extensions (extensions) 27b, 28b of the positive interconnection member 27 and the negative interconnection member 28.  Limitation of the flow of current
suppresses the influence of the flow of current, specifically, influences among the phases.
(4) The widths of the notches 27d, 28d are determined to a value that does not hinder penetration through gel 36.  The notches 27d, 28d allow the gel 36 to flow smoothly, so that the gel 36 efficiently reaches required positions.
(5) Of the main body 27a of the positive interconnection member 27 and the main body 28a of the negative interconnection member 28, which are parallel to the substrate 22, the capacitors 17 are mounted on the main body 28a, which is farther from
the ceramic substrates 21.  Therefore, the capacitors 17 can be integrated with the parts on the substrate 22 including the semiconductor chips 23 serving as switching elements.
(6) The terminal portions 27c, 28c are bonded to the circuit patterns 24b, 24c by ultrasonic bonding, respectively.  Thus, compared to joining by soldering, the produced heat is reduced.
(7) Although the distance between the capacitors 17 and the terminal portions 27c, 28c, which are arranged on the negative interconnection member 28 while being electrically insulated from one another, is small, the terminal portions 27c, 28c
and the circuit patterns 24b, 24c are joined to each other by ultrasonic bonding, which produces less heat than soldering.  Thus, special capacitors with enhanced heat resistance are not required.
A second embodiment of the present invention will now be described with reference to FIGS. 10, 11A, and 11B.  The structure of the second embodiment is different from that of the first embodiment in that the thickness of the downward extensions
27b, 28b extending from the main bodies 27a, 28a of the interconnection members 27, 28 to the substrate and the thickness of the terminal portions 27c, 28c are less than the thickness of the main bodies 27a, 28a.  Those components that are like or the
same as the corresponding components of the first embodiment will not be described.
As in the first embodiment, pairs of downward extensions 27b, 28b are located at ends of the corresponding main body 27a, 28a in the widthwise direction while being bent to extend toward the substrate 22 as shown FIG. 10.  Also, terminal
portions 27c, 28c each extend downward from the lower ends of the downward extensions 27b, 28b, and then extend parallel with the main bodies 27a, 28a.  As shown in FIGS. 11A and 11B, the thickness of the downward extensions 27b, 28b and the thickness of
the terminal portions 27c, 28c are less than the thickness of the main bodies 27a, 28a.  That is, the downward extensions 27b, 28b include bent portions 27b1, 28b1, which are shaped like angle irons in relation to the main bodies 27a, 28a, respectively.
The bent portions 27b1, 28b1 are formed in thin portions of the interconnection members 27, 28.  Being shaped like an angle iron refers to a state in which sections on both sides of the bent portion are arranged to be perpendicular to each other.  The
main bodies 27a, 28a are formed to have a thickness having a necessary capacitance, for example, a thickness of 1 mm.  The downward extensions 27b, 28b and the terminal portions 27c, 28c are formed have a thickness that facilitates bending and ultrasonic
bonding the terminal portions 27c, 28c, for example, a thickness of 0.5 mm.  Although notches 27d, 28d are not illustrated in FIG. 10, a plurality of notches 27d, 28d for limiting the flow of currents may be provided in the downward extensions 27b, 28b
As shown in FIG. 11A and FIG. 11B, the positive interconnection member 27 and the negative interconnection member 28 each have a first surface and a second surface.  The first surface has a step at a position where the thickness changes.  The
second surface is opposite to the first surface.  The positive interconnection member 27 and the negative interconnection member 28 are arranged such that their second surfaces, that is, the surfaces without steps face each other.
The positive interconnection member 27 and the negative interconnection member 28 are formed by pressing belt-like metal plates to form thick portions and thin portions, and then bending the metal plates to form the downward extensions 27b, 28b
and the terminal portions 27c, 28c.
A current the magnitude of which is the sum of currents through the terminal portions 27c, 28c of the main bodies 27a, 28a flows through the main bodies 27a, 28a.  The thickness of the positive interconnection member 27 and the negative
interconnection member 28 is determined to be a value that allows flow of current without hindrance in response to the load requirement.  In a case where the thickness of the downward extensions 27b, 28b and the thickness of the terminal portions 27c,
28c are the same as the thickness of the main bodies 27a, 28a, if the thickness is increased to ensure the required capacitance, the downward extensions 27b, 28b and the terminal portions 27c, 28c are difficult to bend.  However, in the present
embodiment, since the thickness of the downward extensions 27b, 28b and the thickness of the terminal portions 27c, 28c are determined to values that facilitate bending, the downward extensions 27b, 28b and the terminal portions 27c, 28c are easily bent. The current flowing through the terminal portions 27c, 28c is part of the current flowing through the main body 27a, 28a.  That is, the magnitude of the current flowing through the terminal portions 27c, 28c is less than the magnitude of the current
flowing through the main body 27a, 28a.  Thus, although the thickness of the downward extensions 27b, 28b and the thickness of the terminal portions 27c, 28c are set to values that facilitate bending and terminal portions are made suitable for ultrasonic
bonding, a current having a sufficient magnitude is supplied to the semiconductor chips 23 without hindrance.
The present embodiment has the following advantage in addition to the advantages (1) to (7) of the first embodiment.
(8) The downward extensions 27b, 28b include bent portions 27b1, 28b1, which are shaped like angle irons in relation to the main bodies 27a, 28a, respectively.  The downward extensions 27b, 28b are formed thinner than the main bodies 27a, 28a.
Therefore, even if the thickness of the main body 27a, 28a is set to a sufficient value for ensuring the required capacitance, the downward extensions 27b, 28b and the terminal portions 27c, 28c can be bent easily.
(9) The positive interconnection member 27 and the negative interconnection member 28 are arranged such that their second surfaces (the surfaces without steps) face each other.  Therefore, the positive interconnection member 27 and the negative
interconnection member 28 can be insulated from each other while being parallel to and close to each other, not only at the main body 27a, 28a, but also at the remaining portions.  Thus, compared to a case where the interconnection members 27, 28 are
arranged such that a surface without a step and a surface with a step face each other, the interconnection inductance is reduced.
(10) The bent portions 27b1, 28b1 may be formed at the boundary between the thick portion and the thin portion.  However, in the present embodiment, the bent portions 27b1, 28b1 are formed in the thick portion.  Compared to a case where the bent
portions 27b1, 28b1 are formed at the boundary, the downward extensions 27b, 28b are bent easily.  Also, since the bent portions 27b1, 28b1 are formed in thin portions, the radius of curvature of the bent portions 27b1, 28b1 can be made small, so that
the projection amount of the downward extensions 27b, 28b in the widthwise direction of the main bodies 27a, 28a is reduced.  This allows the entire apparatus 11 to be compact.
In the second embodiment, the positive interconnection member 27 and the negative interconnection member 28 arranged such that surfaces without steps face each other.  However, as shown in FIG. 12, the interconnection members 27, 28 may be
arranged such that a surface with a step and a surface without steps face each other.  In a configuration where surfaces without steps face each other, the bending directions of the bent portions 27b1, 28b1 are different in relation to the steps.  Thus,
two kinds of dies for bending are required, which makes the manufacture troublesome and increases the costs.  In contrast, in a configuration where the interconnection members 27, 28 are arranged such that a surface without steps and a surface with a
step face each other, the bending direction of the bent portions 27b1, 28b1 is the same in relation to the step.  Thus, the manufacture is facilitated compared to the case where the bending direction is different between the bent portions 27b1 and 28b1.
A third embodiment of the present invention will now be described with reference to FIGS. 13 to 15B.  The structure of the third embodiment is different from that of the first embodiment in that the terminal portions 27c, 28c are bent such that
the cross-sectional shape of the interconnection members 27, 28 is cranked between the main bodies 27a, 28a and the joint portions 27c1, 28c1, and that the joint portions 27c1, 28c1, at which the terminal portions 27c, 28c contact the circuit patterns
24b, 24c, are arranged at positions spaced from the semiconductor chips 23 on the circuit patterns 24b, 24c by equal distances L1, L2.  Those components that are like or the same as the corresponding components of the first embodiment will not be
As shown in FIGS. 13 to 15B, the terminal portions 27c, 28c are joined to the circuit patterns 24b, 24c at distal ends, that is, at the joint portions 27c1, 28c1 as in the first embodiment.  The terminal portions 27c, 28c are bent such that the
cross-sectional shape of the interconnection members is cranked between the main bodies and the joint portions.  In this description, the cranked shape refers to the shape of a line having two parts that are bent substantially at a right angle.  As shown
in FIG. 15B, the joint portion 27c1 of each terminal portion 27c is arranged to be spaced from a plurality of (two) semiconductor chips 23 arranged on the corresponding circuit pattern 24b by distances L1, L2.  The distances L1, L2 are equal to each
other within tolerance.  In the terminal portions 27c, 28c, the length of a portion that extends upward from the joint portions 27c1, 28c1 at a right angle is determined such that, when a tool for ultrasonic bonding (horn) presses the joint portions
27c1, 28c1, the tool does not interfere with the terminal portions 27c, 28c.  Although notches 27d, 28d are not illustrated in FIG. 14, a plurality of notches 27d, 28d for limiting the flow of currents may be provided in the downward extensions 27b, 28b
The terminal portions 27c, 28c are bent such that the cross-sectional shape of the interconnection members is cranked between the main bodies and the joint portions.  Thus, portions other than the joint portions 27c1, 28c1 do not contact the
circuit patterns 24b, 24c.  Therefore, the distances L1, L2 between each joint portion 27c1 and the corresponding semiconductor chips 23 do not vary, but are equal to each other.
When a force of the direction represented by arrow P in FIG. 15B acts on the terminal portions 27c, 28c, the force is absorbed by elastic deformation of the cranked terminal portions 27c, 28c having two bent portions before reaching the joint
portions 27c1, 28c1.  Thus, stress acting on the joint portions 27c1, 28c1 is reduced.
Also, the cranked terminal portions 27c, 28c allow a tool for ultrasonic bonding to reliably join only the joint portions 27c1, 28c1 along the entire length L by ultrasonic bonding to the corresponding circuit patterns 24b, 24c, without
interfering with the terminal portions 27c, 28c.  This improves the mechanical and electrical stability of the apparatus.
(11) The terminal portions 27c, 28c are bent such that the cross-sectional shape of the interconnection members is cranked between the main bodies and the joint portions, and the joint portion 27c1 of the terminal portion 27c is joined to the
circuit pattern 24b at a position spaced from the semiconductor chips 23 by the same distance.  Therefore, the interconnection inductance is stably equalized, the imbalance of currents supplied to the semiconductor chips 23 is reduced.
Further, since the terminal portions 27c, 28c are bent such that the cross-sectional shape of the interconnection members is cranked between the main bodies and the joint portions, the stress at the joint portions 27c1, 28c1 is reduced.
In place of the insulation sheet 29, a plate-like insulator (for example, a resin plate) may be used.  Further, the positive interconnection member 27 and the negative interconnection member 28 may be entirely insulated by gel.
The positive interconnection member 27 and the negative interconnection member 28 may be joined to the ceramic substrates 21 by method other than ultrasonic bonding, for example, laser welding or soldering.  Likewise, the joining of the output
electrode members 32U, 32V, 32W to the ceramic substrates 21, or the joining the drive input terminals G1 to G6 and the signal terminals S1 to S6 to the ceramic substrates 21 may be achieved by laser welding or soldering.
The arrangement of the main bodies 27a, 28a may be changed as long as the main bodies 27a, 28a are parallel with the substrate 22, close to each other, and insulated from each other.  For example, instead of arranging the main body 28a on the
upper side, or at a position farther from the substrate 22, the main body 27a may be arranged on the upper side.  However, when electrolytic capacitors are used as the capacitors 17, the main body 28a of the negative interconnection member is preferably
located at the top since an outer portion of each electrolytic capacitor, where a shielding material is located, is grounded.
The positions of the capacitors 17 are not limited to positions facing the substrate 22, that is, positions above the metal base 20.  For example, capacitors 17 may be located on the side of the metal base 20.  In this case, the main body 28a of
the negative interconnection member 28 is located closer to the capacitors 17, that is, on the lower side.  The downward extensions 27b, 28b extend downward from the main bodies 27a, 28a, respectively.  The lower ends of the downward extensions 27b, 28b
are bent to form the terminal portions 27c, 28c.  The terminal portions 27c, 28c are joined at the joint portions 27c1, 28c1 to the circuit patterns 24b, 24c for drain and source on the ceramic substrates 21.  In this embodiment, each arm is configured
by two semiconductor chips 23 mounted on one ceramic substrate 21, and six rows of ceramic substrates 21 are arranged along the direction perpendicular to the plane of FIG. 16.  In FIG. 16, the substrate elements other than the circuit pattern 24b or the
output electrode member 32U are not illustrated.  In this case also, in the positive interconnection member 27 and the negative interconnection member 28, the downward extensions 27b, 28b serving as extensions extend from the main bodies 27a, 28a toward
the ceramic substrates 21 and to positions closest to the substrate 21 while being parallel to each other.  This reduces the parasitic inductance in the interconnection of the capacitors.  Further, the downward extensions 27b, 28b have the notches 27d,
28d for limiting the flow of current.  This suppresses the influence of the flow of current, specifically, influences among the phases.  In FIG. 16, solder H for joining the ceramic substrate 21 to the metal base 20 and solder H for joining the
semiconductor chips 23 to the circuit pattern 24b are shown.
Instead of forming each arm by two ceramic substrates 21, each arm may be formed by one ceramic substrate 21.  This structure eliminates the necessity of the wire bonding to electrically connect the gate signal circuit patterns 24a to each other
and the source signal circuit patterns 24d to each other.  Also, the number of joints between each drain circuit pattern 24b and the corresponding terminal portions 27c and the number of joints between each source circuit pattern 24c and the
corresponding terminal portions 28c may be reduced from two to one.  Further, the number of joints between each joint portion 35 and the corresponding one of the drain circuit pattern 24b and the source circuit pattern 24c may be reduced from two to one.
To reduce the number of the ceramic substrates 21, each arm may be formed by one ceramic substrate 21.  Alternatively, two or more arms may be provided on one ceramic substrate 21.
The metal base 20 may be formed of aluminum-based metal, and the ceramic substrates 21 may be DBA (Direct Brazed Aluminum) substrates, which has an aluminum layer on each side.  In this case, the circuit patterns 24a to 24d may be formed on the
upper surface of the DBA substrate, and the lower surface of the DBA substrate may be brazed to the metal base with aluminum-based brazing filler metal.
In place of the ceramic substrates 21, metal substrates with insulation layer on the surface may be used as insulated substrates.  In this case, the circuit patterns 24a to 24d may be formed on the insulation layer.
Instead of joining insulated substrates to the metal base 20 by soldering or brazing, an insulation layer may be formed on the metal base 20, and the circuit patterns 24a to 24d may be formed on the insulation layer.  In this case, the number of
components is reduced, and the step for joining the insulated substrates to the metal base 20 is unnecessary.
The number of pairs of the switching elements Q and the diode D in each arm is not limited to four, but may be less or more than four depending on the amount current through the arm.  Alternatively, each arm may be formed by a single switching
element Q and a single diode D.
Instead of three-phase AC, the inverter apparatus 11 may output single phase AC.  In such a case, two pairs of upper arms and lower arms are provided.
The juncture between the positive terminal 17a of the capacitor 17 and the positive interconnection member 27 the juncture between the negative terminal 17b and the negative interconnection member 28 are not limited to fastening by screws, but
may be achieved by a joining method in which the capacitors 17 are less affected by heat than in soldering.  For example, precision resistance welding or laser beam welding may be employed.
In the third embodiment, the distances L1, L2 between the joint portion 27c1 of the terminal portion 27c and the semiconductor chips 23 are equal to each other within tolerance.  However, the terminal portion 27c may be joined to the circuit
pattern 24b in such a manner that the impedances of the paths of electric current from the terminal portion 27c to the semiconductor chips 23 are equal to each other within tolerance.
As long as the power converter apparatus is configured such that a plurality of switching elements are connected in parallel and plate-like conductors are used as interconnection members, the capacitors 17 may be omitted.
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