Source: https://patents.google.com/patent/JP5557585B2/en
Timestamp: 2020-04-07 07:31:54
Document Index: 388267437

Matched Legal Cases: ['art 406', 'art 19', 'art 19', 'art 19', 'art 19', 'art 19', 'art 608', 'art 601', 'art 602', 'art 602', 'art 602', 'art 602', 'art 342', 'art 339', 'art 340', 'arts 315']

JP5557585B2 - Power module - Google Patents
JP5557585B2
JP5557585B2 JP2010100468A JP2010100468A JP5557585B2 JP 5557585 B2 JP5557585 B2 JP 5557585B2 JP 2010100468 A JP2010100468 A JP 2010100468A JP 2010100468 A JP2010100468 A JP 2010100468A JP 5557585 B2 JP5557585 B2 JP 5557585B2
JP2010100468A
JP2011233606A (en
佑輔 高木
薫 内山
健 徳山
真二 平光
2010-04-26 Application filed by 日立オートモティブシステムズ株式会社 filed Critical 日立オートモティブシステムズ株式会社
2010-04-26 Priority to JP2010100468A priority Critical patent/JP5557585B2/en
2011-11-17 Publication of JP2011233606A publication Critical patent/JP2011233606A/en
2014-07-23 Publication of JP5557585B2 publication Critical patent/JP5557585B2/en
The present invention relates to a power module used in a power converter, and more particularly to a power module mounted on a hybrid vehicle or an electric vehicle.
Since a semiconductor chip for high withstand voltage and large current generates a large amount of heat during use, a configuration for improving heat dissipation from the chip is required. As an example of this configuration, a configuration in which a pair of heat radiating plates is bonded to both surfaces of the chip is considered. According to this configuration, heat radiation can be improved because heat can be radiated from both surfaces of the chip. The entire double-sided heat dissipation type semiconductor device is molded with resin (Patent Document 1).
When this molded semiconductor device is housed in a case and further mounted in a power conversion device, improvement in productivity, connection reliability of terminals, miniaturization, and further improvement in heat dissipation are required.
JP 2007-53295 A
The problem to be solved by the present invention is to improve productivity when housing a resin-molded semiconductor device in a case.
Another problem to be solved by the present invention is to improve the connection reliability of terminals of a resin molded semiconductor device housed in a case.
Another problem to be solved by the present invention is to reduce the size and heat dissipation of a resin-molded semiconductor device housed in a case.
In order to solve the above problems, a power module according to the present invention includes a semiconductor element, a first conductor plate connected to one electrode surface of the semiconductor element via solder, the semiconductor element, and the first conductor. A sealing body having a sealing material for sealing the plate, and a case for housing the sealing body, the case facing a first surface of the sealing body. 1 heat radiating plate, a second heat radiating plate facing the other surface opposite to the one surface of the sealing body, and an intermediate member connecting the first heat radiating plate and the second heat radiating plate. The intermediate member has a thickness that is smaller than the thickness of the first heat radiating plate, is elastically deformed more easily than the first heat radiating plate, and is formed so as to surround the first heat radiating plate. And the sealing body has the first heat radiating plate by an elastic force generated in the first thin portion. It is fixed by being pressed to the second heat radiating plate via.
According to the present invention, the productivity of the power module can be further improved.
It is a figure which shows the control block of a hybrid vehicle. It is the control block diagram and circuit block diagram at the time of applying to a hybrid vehicle. The disassembled perspective view for demonstrating the installation place of the power converter device 200 which concerns on this embodiment is shown. It is the perspective view which decomposed | disassembled the whole structure of the power converter device which concerns on this embodiment into each component. 4 is a bottom view of the cooling jacket 12 having a flow path 19. FIG. (A) is a perspective view of the power module 300a of this embodiment. (B) is sectional drawing of the power module 300a of this embodiment. (A) is internal sectional drawing which removed the module case 304, the insulating sheet 333, and the 2nd sealing resin 351, in order to help an understanding. (B) is the internal perspective view which removed the 1st sealing resin 348 from (a). (A) is a perspective view of the module primary sealing body 302. FIG. (B) is sectional drawing of the module case 304 seen from the cross section A of Fig.6 (a). (A) thru | or (d) are process drawings which showed the process of inserting the module primary sealing body 302 in the module case 304. FIG. (A) is a perspective view of the auxiliary mold body 600, and (b) is a transparent view of the auxiliary mold body 600. It is a disassembled perspective view of the capacitor module 500 of this embodiment. 3 is an external perspective view in which a power module 300, a capacitor module 500, and a bus bar assembly 800 are assembled to a flow path forming body 12. FIG. It is an enlarged view of the part A of FIG. 4 is an exploded perspective view of a flow path forming body 12 and a bus bar assembly 800 assembled with a power module 300 and a capacitor module 500. FIG. It is an external perspective view of the bus bar assembly 800 excluding the holding member 803. FIG. 3 is an external perspective view of a state where a power module, a capacitor module, a bus bar assembly 800, and an auxiliary power module 350 are assembled to a flow path forming body 12. It is a perspective view of the state which separated the control circuit board 20 and the metal base board 11 in order to help an understanding. It is sectional drawing which looked at the power converter device 200 of the surface shown with the broken line B of FIG. 17 from C direction. It is sectional drawing of the power converter device 200 which passes along the inlet piping 13 and the outlet piping 14 of FIG. (A) is a perspective view of the module case 370 which concerns on 2nd Embodiment. (B) is sectional drawing of the module case 370 seen from the cross section A of (a). 5 is a process diagram showing a process of inserting a module primary sealing body 302 into a module case 370. FIG. (A) is a perspective view of the module case 371 which concerns on 3rd Embodiment. (B) is sectional drawing of the module case 371 seen from the cross section A of (a). FIG. 10 is a process diagram showing a process of inserting the module primary sealing body 302 into the module case 371. (A) is a perspective view of the module case 372 which concerns on 4th Embodiment. (B) is a diagram showing the inside of the module case 372 as seen from the direction of arrow B. (C) is sectional drawing of the module case 371 seen from the cross section A of (a). (A) is a perspective view of the module primary sealing body 380 which concerns on 5th Embodiment. (B) is sectional drawing of the module primary sealing body 380 which passes along the line A of (a). (A) is a perspective view of the module case 374 which concerns on 5th Embodiment. (B) is sectional drawing of the module case 373 seen from the cross section A of (a). FIG. 11 is a process diagram showing a process of inserting a module primary sealing body 380 into a module case 374. (A) is a perspective view of the module primary sealing body 381 which concerns on 6th Embodiment. (B) is sectional drawing of the module primary sealing body 381 which passes along the line A of (a). (A) is a perspective view of the module case 375 which concerns on 6th Embodiment. (B) is the front view seen from the formation surface of the fin 305 of the module case 375. FIG. (C) is sectional drawing of the module case 375 seen from the cross section A of (a). It is a process diagram showing a process of inserting the module primary sealing body 381 into the module case 375.
FIG. 1 is a diagram showing a control block of a hybrid vehicle (hereinafter referred to as “HEV”). Engine EGN and motor generator MG1 and motor generator MG2 generate vehicle running torque. Motor generator MG1 and motor generator MG2 not only generate rotational torque, but also have a function of converting mechanical energy applied from the outside to motor generator MG1 or motor generator MG2 into electric power.
The motor generator MG1 or MG2 is, for example, a synchronous machine or an induction machine, and operates as a motor or a generator depending on the operation method as described above. When the motor generator MG1 or MG2 is mounted on an automobile, it is desirable to obtain a small and high output, and a permanent magnet type synchronous motor using a magnet such as neodymium is suitable. In addition, the permanent magnet type synchronous motor generates less heat from the rotor than the induction motor, and is excellent for automobiles from this viewpoint.
The output torque of the engine EGN and the output torque of the motor generator MG2 are transmitted to the motor generator MG1 via the power distribution mechanism TSM, and the rotation torque from the power distribution mechanism TSM or the rotation torque generated by the motor generator MG1 is the transmission TM and the differential. It is transmitted to the wheel via the gear DEF. On the other hand, during regenerative braking operation, rotational torque is transmitted from the wheels to motor generator MG1, and AC power is generated based on the supplied rotational torque. The generated AC power is converted into DC power by the power conversion device 200 as described later, and the high-voltage battery 136 is charged. The charged power is used again as travel energy. When the power stored in the high-voltage battery 136 is reduced, the rotational energy generated by the engine EGN is converted into AC power by the motor generator MG2, and then the AC power is converted into DC power by the power converter 200. And the battery 136 can be charged. Transmission of mechanical energy from engine EGN to motor generator MG2 is performed by power distribution mechanism TSM.
Next, the power conversion device 200 will be described. The inverter circuits 140 and 142 are electrically connected to the battery 136 via the DC connector 138, and power is exchanged between the battery 136 and the inverter circuit 140 or 142. When motor generator MG1 is operated as a motor, inverter circuit 140 generates AC power based on DC power supplied from battery 136 via DC connector 138 and supplies it to motor generator MG1 via AC terminal 188. . The configuration comprising motor generator MG1 and inverter circuit 140 operates as a first motor generator unit. Similarly, when motor generator MG2 is operated as a motor, inverter circuit 142 generates AC power based on the DC power supplied from battery 136 via DC connector 138, and is supplied to motor generator MG2 via AC terminal 159. Supply. The configuration composed of motor generator MG2 and inverter circuit 142 operates as a second motor generator unit. The first motor generator unit and the second motor generator unit may be operated as both motors or generators depending on the operating state, or may be operated using both of them. It is also possible to stop without driving one. In the present embodiment, the first motor generator unit is operated as the electric unit by the electric power of the battery 136, so that the vehicle can be driven only by the power of the motor generator MG1. Furthermore, in the present embodiment, the battery 136 can be charged by generating power by operating the first motor generator unit or the second motor generator unit as the power generation unit by the power of the engine 120 or the power from the wheels.
The battery 136 is also used as a power source for driving an auxiliary motor 195. The auxiliary motor 195 is, for example, a motor that drives a compressor of an air conditioner or a motor that drives a control hydraulic pump. DC power is supplied from the battery 136 to the auxiliary power module 350, AC power is generated by the auxiliary power module 350, and is supplied to the auxiliary motor 195 through the AC terminal 120. The auxiliary power module 350 basically has the same circuit configuration and function as the inverter circuits 140 and 142, and controls the phase, frequency, and power of alternating current supplied to the auxiliary motor 195. Since the capacity of the auxiliary motor 195 is smaller than the capacity of the motor generators MG1 and MG2, the maximum conversion power of the auxiliary power module 350 is smaller than that of the inverter circuits 140 and 142. The basic configuration and basic operation are substantially the same as those of the inverter circuits 140 and 142. The power conversion device 200 includes a capacitor module 500 for smoothing DC power supplied to the inverter circuit 140, the inverter circuit 142, and the inverter circuit 350B.
The power conversion device 200 includes a communication connector 21 for receiving a command from a host control device or transmitting data representing a state to the host control device. Based on the command from the connector 21, the control circuit 172 calculates the control amount of the motor generator MG1, the motor generator MG2, and the auxiliary motor 195, and further calculates whether to operate as a motor or a generator. A control pulse is generated based on the result, and the control pulse is supplied to the driver circuit 174 and the driver circuit 350B of the accessory module 350. The auxiliary module 350 may have a dedicated control circuit. In this case, the dedicated control circuit generates a control pulse based on a command from the connector 21, and sends the control pulse to the driver circuit 350 B of the auxiliary module 350. Supply. Based on the control pulse, the driver circuit 174 generates a drive pulse for controlling the inverter circuit 140 and the inverter circuit 142. The driver circuit 350A generates a control pulse for driving the inverter circuit 350B of the auxiliary power module 350.
Next, the configuration of the electric circuit of the inverter circuit 140 and the inverter circuit 142 will be described with reference to FIG. Since the circuit configuration of the inverter 350B of the auxiliary power module 350 shown in FIG. 1 is basically similar to the circuit configuration of the inverter circuit 140, the description of the specific circuit configuration of the inverter 350B is omitted in FIG. The inverter circuit 140 will be described as a representative example. However, since the power module 350 for auxiliary machinery has a small output power, the semiconductor chips constituting the upper arm and lower arm of each phase described below and the circuit for connecting the chips are integrated in the power module 350 for auxiliary machinery. Has been placed.
Further, since the inverter circuit 140 and the inverter circuit 142 are very similar in circuit configuration and operation, the inverter circuit 140 will be described as a representative.
In the following, an insulated gate bipolar transistor is used as a semiconductor element, and hereinafter abbreviated as IGBT. The inverter circuit 140 includes a U-phase, a V-phase of AC power to be output from a series circuit 150 of upper and lower arms composed of an IGBT 328 and a diode 156 that operate as an upper arm, and an IGBT 330 and a diode 166 that operate as a lower arm. Corresponding to three phases consisting of W phase. In this embodiment, these three phases correspond to the three-phase windings of the armature winding of motor generator MG1. The series circuit 150 of the upper and lower arms of each of the three phases outputs an alternating current from the intermediate electrode 169 that is the middle point portion of the series circuit, and this alternating current is supplied to the motor generator MG1 through the alternating current terminal 159 and the alternating current terminal 188. An AC power line is connected to AC bus bars 802 and 804 described below.
The collector electrode 153 of the IGBT 328 in the upper arm is connected to the capacitor terminal 506 on the positive electrode side of the capacitor module 500 through the positive electrode terminal 157, and the emitter electrode of the IGBT 330 in the lower arm is connected to the capacitor terminal on the negative electrode side of the capacitor module 500 through the negative electrode terminal 158. 504 are electrically connected to each other.
As described above, the control circuit 172 receives a control command from the host control device via the connector 21, and based on this, the IGBT 328 that configures the upper arm or the lower arm of each phase series circuit 150 that constitutes the inverter circuit 140. And a control pulse that is a control signal for controlling the IGBT 330 is generated and supplied to the driver circuit 174. Based on the control pulse, the driver circuit 174 supplies a drive pulse for controlling the IGBT 328 and IGBT 330 constituting the upper arm or the lower arm of each phase series circuit 150 to the IGBT 328 and IGBT 330 of each phase. IGBT 328 and IGBT 330 perform conduction or cutoff operation based on the drive pulse from driver circuit 174, convert DC power supplied from battery 136 into three-phase AC power, and supply the converted power to motor generator MG1. Is done.
The IGBT 328 includes a collector electrode 153, a signal emitter electrode 155, and a gate electrode 154. The IGBT 330 includes a collector electrode 163, a signal emitter electrode 165, and a gate electrode 164. A diode 156 is electrically connected between the collector electrode 153 and the emitter electrode 155. A diode 166 is electrically connected between the collector electrode 163 and the emitter electrode 165. As the switching power semiconductor element, a metal oxide semiconductor field effect transistor (hereinafter abbreviated as MOSFET) may be used. In this case, the diode 156 and the diode 166 are unnecessary. As a switching power semiconductor element, IGBT is suitable when the DC voltage is relatively high, and MOSFET is suitable when the DC voltage is relatively low.
The capacitor module 500 includes a plurality of capacitor terminals 506 on the positive electrode side, a plurality of capacitor terminals 504 on the negative electrode side, a power supply terminal 509 on the positive electrode side, and a power supply terminal 508 on the negative electrode side. The high-voltage DC power from the battery 136 is supplied to the positive power supply terminal 509 and the negative power supply terminal 508 via the DC connector 138, and the plurality of positive capacitor terminals 506 and the plurality of capacitor terminals 506 of the capacitor module 500 are supplied. It is supplied from the capacitor terminal 504 on the negative electrode side to the inverter circuit 140, the inverter circuit 142, and the auxiliary module 350. On the other hand, the DC power converted from the AC power by the inverter circuit 140 or the inverter circuit 142 is supplied to the capacitor module 500 from the positive capacitor terminal 506 or the negative capacitor terminal 504, and is supplied to the positive power supply terminal 509 or negative electrode side. Are supplied to the battery 136 from the power supply terminal 508 via the DC connector 138 and stored in the battery 136.
The control circuit 172 includes a microcomputer (hereinafter referred to as “microcomputer”) for calculating the switching timing of the IGBT 328 and the IGBT 330. As input information to the microcomputer, there are a target torque value required for the motor generator MG1, a current value supplied from the upper and lower arm series circuit 150 to the motor generator MG1, and a magnetic pole position of the rotor of the motor generator MG1. The target torque value is based on a command signal output from a host controller (not shown). The current value is detected based on a detection signal from the current sensor 180. The magnetic pole position is detected based on a detection signal output from a rotating magnetic pole sensor (not shown) such as a resolver provided in the motor generator MG1. In this embodiment, the current sensor 180 detects the current value of three phases, but the current value for two phases may be detected and the current for three phases may be obtained by calculation. .
The microcomputer in the control circuit 172 calculates the d and q axis current command values of the motor generator MG1 based on the target torque value, and the calculated d and q axis current command values and the detected d and q The voltage command values for the d and q axes are calculated based on the difference from the current value of the shaft, and the calculated voltage command values for the d and q axes are calculated based on the detected magnetic pole position. Convert to W phase voltage command value. Then, the microcomputer generates a pulse-like modulated wave based on the comparison between the fundamental wave (sine wave) and the carrier wave (triangular wave) based on the voltage command values of the U-phase, V-phase, and W-phase, and the generated modulation The wave is output to the driver circuit 174 as a PWM (pulse width modulation) signal. When driving the lower arm, the driver circuit 174 outputs a drive signal obtained by amplifying the PWM signal to the gate electrode of the corresponding IGBT 330 of the lower arm. Further, when driving the upper arm, the driver circuit 174 amplifies the PWM signal after shifting the level of the reference potential of the PWM signal to the level of the reference potential of the upper arm, and uses this as a drive signal as a corresponding upper arm. Are output to the gate electrodes of the IGBTs 328 respectively.
Further, the microcomputer in the control circuit 172 detects abnormality (overcurrent, overvoltage, overtemperature, etc.) and protects the upper and lower arm series circuit 150. For this reason, sensing information is input to the control circuit 172. For example, information on the current flowing through the emitter electrodes of the IGBTs 328 and IGBTs 330 is input to the corresponding drive unit (IC) from the signal emitter electrode 155 and the signal emitter electrode 165 of each arm. Thereby, each drive part (IC) detects overcurrent, and when overcurrent is detected, it stops the switching operation of corresponding IGBT328 and IGBT330, and protects corresponding IGBT328 and IGBT328330 from overcurrent. Information on the temperature of the upper and lower arm series circuit 150 is input to the microcomputer from a temperature sensor (not shown) provided in the upper and lower arm series circuit 150. In addition, voltage information on the DC positive side of the upper and lower arm series circuit 150 is input to the microcomputer. The microcomputer performs over-temperature detection and over-voltage detection based on the information, and stops switching operations of all the IGBTs 328 and IGBTs 330 when an over-temperature or over-voltage is detected.
FIG. 3 shows an exploded perspective view of a power conversion device 200 as an embodiment according to the present invention. The power conversion device 200 includes a housing 10 having a bottom made of aluminum and a lid 8 for housing circuit components of the power conversion device 200 fixed to the transmission TM. Since the power converter 200 has a substantially rectangular shape on the bottom and top surfaces, it can be easily attached to the vehicle and can be easily produced. The flow path forming body 12 holds a power module 300 and a capacitor module 500, which will be described later, and cools them with a cooling medium. Further, the flow path forming body 12 is fixed to the housing 10, and an inlet pipe 13 and an outlet pipe 14 are provided at the bottom of the housing 10. Water as a cooling medium flows into the flow path forming body 12 from the inlet pipe 13 and flows out from the outlet pipe 14 after being used for cooling.
The lid 8 accommodates circuit components constituting the power conversion device 200 and is fixed to the housing 10. A control circuit board 20 on which a control circuit 172 is mounted is disposed on the inside of the lid 8. The lid 8 is provided with a first opening 202 and a second opening 204 connected to the outside, and the connector 21 is connected to an external control device via the first opening 202 and provided on the control circuit board 20. Signal transmission is performed between the control circuit 172 and an external control device such as a host control device. Low voltage DC power for operating the control circuit in the power converter 200 is supplied from the connector 21. The second opening 204 is provided with a DC connector 138 for transmitting and receiving DC power to and from the battery 136, and a negative power line 510 and a positive electrode for supplying high voltage DC power into the power converter 200. The side power line 512 electrically connects the battery 136 and a DC connector 138 that transmits and receives DC power to the capacitor module 500 and the like.
The connector 21, the negative power line 510 and the positive power line 512 are extended toward the bottom surface of the lid 8, the connector 21 protrudes from the first opening 202, and the leading ends of the negative power line 510 and the positive power line 512 are Projecting from the second opening 204 constitutes a terminal of the DC connector 138. The lid 8 is provided with a seal member (not shown) around the first opening 202 and the second opening 204 on the inner wall thereof. The orientation of the mating surfaces of the terminals of the connector 21 and the like varies depending on the vehicle model. However, particularly when mounting on a small vehicle, the mating surface is selected from the viewpoint of the size restriction in the engine room and the assemblability. It is preferable to make it upward. In particular, when the power conversion device 200 is disposed above the transmission TM as in the present embodiment, workability is improved by projecting toward the opposite side of the transmission TM. In addition, the connector 21 needs to be sealed from the outside atmosphere, but when the lid 8 is assembled to the connector 21 from above, the lid 8 comes into contact with the lid 8 when the lid 8 is assembled to the housing 10. The sealing member which presses can press the connector 21, and airtightness improves.
FIG. 4 is an exploded perspective view for facilitating understanding of the configuration housed in the housing 10 of the power conversion device 200. A flow path 19 shown in FIG. 5 is formed in the flow path forming body 12 along both sides. Openings 400 a to 400 c are formed on the upper surface on one side of the flow path 19 along the refrigerant flow direction 418, and openings 402 a to 402 c are formed on the upper surface on the other side of the flow path 19. It is formed along the flow direction 422. The openings 400a to 400c are closed by the inserted power modules 300a to 300c, and the openings 402a to 402c are closed by the inserted power modules 301a to 301c.
A storage space 405 for storing the capacitor module 500 is formed between one and the other flow paths formed by the flow path forming body 12. By storing the capacitor module 500 in the storage space 405, the capacitor module 500 is cooled by the refrigerant flowing in the flow path 19. In addition, since the flow path for flowing the refrigerant is formed along the outer surface of the capacitor module 500, the cooling efficiency is improved, and the arrangement of the flow path, the capacitor module 500, and the power modules 300 and 301 is neatly arranged. It becomes smaller. Further, the flow path 19 is arranged along the long side of the capacitor module 500, and the distance between the flow path 19 and the power modules 300 and 301 inserted and fixed in the flow path 19 is substantially constant. The circuit constant with the module circuit is easily balanced in each of the three-phase layers, and the circuit configuration is easy to reduce the spike voltage. In the present embodiment, water is most suitable as the refrigerant. However, since it can be used other than water, it will be referred to as a refrigerant hereinafter.
The flow path forming body 12 is provided with a cooling unit 407 provided therein with a space for changing the flow of the refrigerant at a position facing the inlet pipe 13 and the outlet pipe 14. The cooling unit 407 is formed integrally with the flow path forming body 12 and is used for cooling the auxiliary power module 350 in this embodiment. The auxiliary power module 350 is fixed to the cooling surface that is the outer peripheral surface of the cooling unit 407, stores the refrigerant in a space formed inside the cooling surface, and the cooling unit 407 is cooled by this refrigerant, thereby The temperature rise of the module 350 is suppressed. The refrigerant is a refrigerant that flows through the flow path 19, and the auxiliary module 350 is cooled together with the power modules 300 and 301 and the capacitor module 500. A bus bar assembly 800 described later is disposed on both sides of the auxiliary power module 350. The bus bar assembly 800 includes an AC bus bar 186 and a holding member, and holds and fixes the current sensor 180. Details will be described later.
In this way, the storage space 405 of the capacitor module 500 is provided in the center of the flow path forming body 12, the flow paths 19 are provided so as to sandwich the storage space 405, and the vehicle driving power modules 300 a to 300- 300c and power modules 301a to 301c are arranged, and further, the auxiliary power module 350 is arranged on the upper surface of the flow path forming body 12, so that cooling can be efficiently performed in a small space, and the entire power conversion device can be downsized. Become.
Further, by making the main structure of the flow path 19 of the flow path forming body 12 integrally with the flow path forming body 12 by casting an aluminum material, the flow path 19 has an effect of increasing the mechanical strength in addition to the cooling effect. Moreover, by making it by aluminum casting, the flow path forming body 12 and the flow path 19 have an integral structure, heat conduction is improved, and cooling efficiency is improved. The power modules 300a to 300c and the power modules 301a to 301c are fixed to the flow path 19 to complete the flow path 19, and a water leak test is performed on the water channel. When the water leakage test is passed, the work of attaching the capacitor module 500, the auxiliary power module 350, and the substrate can be performed next. In this way, the flow path forming body 12 is disposed at the bottom of the power conversion device 200, and then the work of fixing necessary components such as the capacitor module 500, the auxiliary power module 350, the bus bar assembly 800, and the substrate is performed from the top. It is configured so that it can be performed sequentially, improving productivity and reliability.
The driver circuit board 22 is disposed above the auxiliary power module 350 and the bus bar assembly 800, that is, on the lid side. A metal base plate 11 is disposed between the driver circuit board 22 and the control circuit board 20, and the metal base board 11 functions as an electromagnetic shield for a circuit group mounted on the driver circuit board 22 and the control circuit board 20. At the same time, the heat generated by the driver circuit board 22 and the control circuit board 20 is released and cooled. Further, it acts to increase the mechanical resonance frequency of the control circuit board 20. That is, it becomes possible to dispose screwing portions for fixing the control circuit board 20 to the metal base plate 11 at short intervals, shorten the distance between the support points when mechanical vibration occurs, and reduce the resonance frequency. Can be high. Since the resonance frequency of the control circuit board 20 can be increased with respect to the vibration frequency transmitted from the transmission, it is difficult to be affected by vibration and the reliability is improved.
FIG. 5 is an explanatory diagram for explaining the flow path forming body 12, and is a view of the flow path forming body 12 shown in FIG. 4 as viewed from below. The flow path forming body 12 and the flow path 19 formed inside the flow path forming body 12 along the storage space 405 (see FIG. 4) of the capacitor module 500 are integrally cast. One continuous opening 404 is formed on the lower surface of the flow path forming body 12, and the opening 404 is closed by a lower cover 420 having an opening at the center. A seal member 409a and a seal member 409b are provided between the lower cover 420 and the flow path forming body 12 to maintain airtightness.
An inlet hole 401 for inserting the inlet pipe 13 (see FIG. 4) and the outlet pipe 14 (see FIG. 4) are inserted into the lower cover 420 in the vicinity of one end side and along the one side. An outlet hole 403 is formed. Further, the lower cover 420 is formed with a convex portion 406 that protrudes in the arrangement direction of the transmission TM. The convex part 406 is provided corresponding to the power modules 300a to 300c and the power modules 301a to 301c. The refrigerant flows in the direction of the flow direction 417 indicated by the dotted line through the inlet hole 401 toward the first flow path portion 19a formed along the short side of the flow path forming body 12. The first flow path portion 19a forms a space for changing the flow of the refrigerant, and collides with the inner surface of the cooling portion 407 in the space to change the flow direction. At the time of the collision, the cooling section 407 is deprived of heat. Then, the refrigerant flows through the second flow path portion 19 b formed along the side in the longitudinal direction of the flow path forming body 12 as in the flow direction 418. Further, the refrigerant flows through the third flow path portion 19 c formed along the short side of the flow path forming body 12 as in the flow direction 421. The third flow path portion 19c forms a folded flow path. In addition, the refrigerant flows through the fourth flow path portion 19 d formed along the longitudinal side of the flow path forming body 12 as in the flow direction 422. The fourth flow path portion 19d is provided at a position facing the second flow path portion 19b with the capacitor module 500 interposed therebetween. Further, the refrigerant flows out to the outlet pipe 14 through the fifth flow path portion 19e and the outlet hole 403 formed along the short side of the flow path forming body 12 as in the flow direction 423.
The first flow path part 19a, the second flow path part 19b, the third flow path part 19c, the fourth flow path part 19d, and the fifth flow path part 19e are all formed larger in the depth direction than in the width direction. The power modules 300a to 300c are inserted from the openings 400a to 400c formed on the upper surface side of the flow path forming body 12 (see FIG. 4) and stored in the storage space in the second flow path section 19b. An intermediate member 408a is formed between the storage space of the power module 300a and the storage space of the power module 300b so as not to stagnate the refrigerant flow. Similarly, an intermediate member 408b is formed between the storage space of the power module 300b and the storage space of the power module 300c so as not to stagnate the refrigerant flow. The intermediate member 408a and the intermediate member 408b are formed such that their main surfaces are along the flow direction of the refrigerant. Similarly to the second flow path portion 19b, the fourth flow path portion 19d forms a storage space and an intermediate member for the power modules 301a to 301c. Moreover, since the flow path formation body 12 is formed so that the opening 404 and the openings 400a to 400c and 402a to 402c face each other, the flow path forming body 12 is configured to be easily manufactured by aluminum casting.
The lower cover 420 is provided with a support portion 410 a and a support portion 410 b that are in contact with the housing 10 and support the power conversion device 200. The support portion 410 a is provided close to one end side of the lower cover 420, and the support portion 410 b is provided close to the other end side of the lower cover 420. Thereby, the flow path forming body 12 of the power conversion device 200 can be firmly fixed to the inner wall of the housing 10 formed in accordance with the cylindrical shape of the transmission TM or the motor generator MG1.
Further, the support portion 410b is configured to support the resistor 450. The resistor 450 is for discharging electric charges charged in the capacitor cell in consideration of occupant protection and safety during maintenance. The resistor 450 is configured to continuously discharge high-voltage electricity. However, in the unlikely event that there is any abnormality in the resistor or discharge mechanism, consideration was given to minimize damage to the vehicle. Must be configured. In other words, when the resistor 450 is arranged around the power module, the capacitor module, the driver circuit board, etc., there is a possibility that the resistor 450 may spread near the main component in the event that the resistor 450 has a problem such as heat generation or ignition. Conceivable.
Therefore, in the present embodiment, the power modules 300a to 300c, the power modules 301a to 301c, and the capacitor module 500 are arranged on the opposite side of the housing 10 housing the transmission TM with the flow path forming body 12 interposed therebetween, and resistors 450 is disposed in a space between the flow path forming body 12 and the housing 10. As a result, the resistor 450 is disposed in a closed space surrounded by the flow path forming body 12 and the housing 10 formed of metal. The electric charge stored in the capacitor cell in the capacitor module 500 passes through the wiring passing through the side portion of the flow path forming body 12 by the switching operation of the switching means mounted on the driver circuit board 22 shown in FIG. Discharge is controlled by the resistor 450. In the present embodiment, the switching is controlled so as to discharge at high speed. Since the flow path forming body 12 is provided between the driver circuit board 22 that controls the discharge and the resistor 450, the driver circuit board 22 can be protected from the resistor 450. In addition, since the resistor 450 is fixed to the lower cover 420, the resistor 450 is provided at a position very close to the flow path 19 thermally, so that abnormal heat generation of the resistor 450 can be suppressed.
Detailed configurations of the power modules 300a to 300c and the power modules 301a to 301c used in the inverter circuit 140 and the inverter circuit 142 will be described with reference to FIGS. The power modules 300a to 300c and the power modules 301a to 301c all have the same structure, and the structure of the power module 300a will be described as a representative. 6 to 7, the signal terminal 325U corresponds to the gate electrode 154 and the signal emitter electrode 155 disclosed in FIG. 2, and the signal terminal 325L corresponds to the gate electrode 164 and the emitter electrode 165 disclosed in FIG. To do. The DC positive terminal 315B is the same as the positive terminal 157 disclosed in FIG. 2, and the DC negative terminal 319B is the same as the negative terminal 158 disclosed in FIG. The AC terminal 321 is the same as the AC terminal 159 disclosed in FIG.
FIG. 6A is a perspective view of the power module 300a of the present embodiment. FIG. 6B is a cross-sectional view of the power module 300a of the present embodiment.
The power semiconductor elements (IGBT 328, IGBT 330, diode 156, and diode 166) constituting the upper and lower arm series circuit 150, as shown in FIGS. 6 to 7, are formed by the conductor plate 315 or the conductor plate 318 or the conductor plate 316 or the conductor plate. By 319, it is fixed by being sandwiched from both sides. These conductor plates are assembled with an auxiliary molded body 600 formed by integrally molding signal wirings which are the signal terminals 325U and 325L. The conductor plate 315 and the like are sealed with the first sealing resin 348 with the heat dissipation surface exposed, and the insulating sheet 333 is thermocompression bonded to the heat dissipation surface. The module primary sealing body 302 sealed with the first sealing resin 348 is inserted into the module case 304 and sandwiched with the insulating sheet 333, and is thermocompression bonded to the inner surface of the module case 304 that is a CAN type cooler. The Here, the CAN-type cooler is a cylindrical cooler having an insertion port 306 on one surface and a bottom on the other surface.
The module case 304 is made of an aluminum alloy material such as Al, AlSi, AlSiC, Al—C, and the like, and is integrally formed without a joint. The module case 304 has a structure in which no opening other than the insertion port 306 is provided, and the outer periphery of the insertion port 306 is surrounded by a flange 304B. Further, as shown in FIG. 6 (a), the first heat radiating body 307A and the second heat radiating body 307B having a surface wider than the other surfaces are arranged facing each other, and the facing first heat radiating body 307A and The three surfaces connected to the second heat radiator 307B constitute a surface sealed with a narrower width than the first heat radiator 307A and the second heat radiator 307B, and the insertion port 306 is formed on the remaining one surface. The shape of the module case 304 does not need to be an accurate rectangular parallelepiped, and the corner may form a curved surface as shown in FIG.
By using the metal case having such a shape, even when the module case 304 is inserted into the flow path 19 through which a coolant such as water or oil flows, a seal against the coolant can be secured by the flange 304B. Can be prevented from entering the inside of the module case 304 with a simple configuration. In addition, the fins 305 are uniformly formed on the first heat radiator 307A and the second heat radiator 307B facing each other. Further, a thin portion 304A having an extremely thin thickness is formed on the outer circumferences of the first radiator 307A and the second radiator 307B. Since the thin portion 304A is extremely thin to such an extent that it can be easily deformed by pressurizing the fin 305, the productivity after the module primary sealing body 302 is inserted is improved.
The gap remaining inside the module case 304 is filled with the second sealing resin 351. Further, as shown in FIGS. 8 and 9, a DC positive electrode wiring 315A and a DC negative electrode wiring 319A for electrical connection with the capacitor module 500 are provided, and a DC positive electrode terminal 315B (157) is provided at the tip thereof. DC negative terminal 319B (158) is formed. An AC wiring 320 for supplying AC power to the motor generator MG1 or MG2 is provided, and an AC terminal 321 (159) is formed at the tip thereof. In the present embodiment, the DC positive electrode wiring 315A is integrally formed with the conductor plate 315, the DC negative electrode wiring 319A is integrally formed with the conductor plate 319, and the AC wiring 320 is integrally formed with the conductor plate 316.
As described above, by thermally pressing the conductor plate 315 or the like to the inner wall of the module case 304 via the insulating sheet 333, the gap between the conductor plate and the inner wall of the module case 304 can be reduced, and the power semiconductor element The generated heat can be efficiently transmitted to the fins 305. Further, by providing the insulating sheet 333 with a certain degree of thickness and flexibility, the generation of thermal stress can be absorbed by the insulating sheet 333, which is favorable for use in a power conversion device for a vehicle having a large temperature change. .
FIG. 7A is an internal cross-sectional view in which the module case 304, the insulating sheet 333, and the second sealing resin 351 have been removed to facilitate understanding. FIG. 7B is an internal perspective view in which the first sealing resin 348 is removed from FIG.
Each power semiconductor element is fixed to an element fixing portion 322 provided on each conductor plate via a metal bonding material 160. The metal bonding material 160 is, for example, a low-temperature sintered bonding material including a solder material, a silver sheet, and fine metal particles.
Each power semiconductor element has a flat plate-like structure, and each electrode of the power semiconductor element is formed on the front and back surfaces. As shown in FIG. 7, each electrode of the power semiconductor element is sandwiched between a conductor plate 315 and a conductor plate 318, or a conductor plate 316 and a conductor plate 319. In other words, the conductor plate 315 and the conductor plate 318 are stacked so as to face each other substantially in parallel via the IGBT 328 and the diode 156. Similarly, the conductor plate 316 and the conductor plate 319 have a stacked arrangement facing each other substantially in parallel via the IGBT 330 and the diode 166. Further, the conductor plate 316 and the conductor plate 318 are connected via an intermediate electrode 329. By this connection, the upper arm circuit and the lower arm circuit are electrically connected to form an upper and lower arm series circuit. The heat radiating surface 323 is exposed from the first sealing resin 348 and covered with the insulating sheet shown in FIG.
The direct current positive electrode wiring 315A and the direct current negative electrode wiring 319A have a shape extending substantially in parallel with the auxiliary mold body 600 formed of a resin material facing each other. The signal terminal 325U and the signal terminal 325L are formed integrally with the auxiliary mold body 600 and extend in the same direction as the DC positive electrode wiring 315A and the DC negative electrode wiring 319A. As the resin material used for the auxiliary mold body 600, a thermosetting resin having an insulating property or a thermoplastic resin is suitable. As a result, it is possible to ensure insulation between the DC positive electrode wiring 315A, the DC negative electrode wiring 319A, the signal terminal 325U, and the signal terminal 325L, thereby enabling high-density wiring. Furthermore, the direct current positive electrode wiring 315A and the direct current negative electrode wiring 319A are arranged so as to face each other substantially in parallel, so that currents that instantaneously flow during the switching operation of the power semiconductor element face each other in the opposite direction. As a result, the magnetic fields produced by the currents cancel each other out, and this action can reduce the inductance.
FIG. 8A is a perspective view of the module primary sealing body 302. FIG. 8B is a cross-sectional view of the module case 304 as viewed from the cross-section A of FIG.
In order to efficiently cool the semiconductor element, a gap should not be generated between the conductor plates 315, 316, 318, and 319 to which the semiconductor element is connected and the first and second radiators 307A and 307B. Is important. However, since the thickness 303 of the module primary sealing body 302 varies, a gap is easily formed between the module primary sealing body 302 and the first heat radiating body 307A and the second heat radiating body 307B, resulting in a decrease in cooling performance. I will do it. On the other hand, if high-precision parts are used in order to reduce the variation in the thickness 303, or high-precision assembly and processing are performed, productivity improvement and cost reduction are hindered.
As shown in FIG. 8B, the module case 304 has a thin-walled portion 304A that connects the flange 304B, the first heat radiator 307A, and the second heat radiator 307B. The module case 304 has a thin portion 304A that connects the frame body 308 to the first heat radiator 307A and the second heat radiator 307B. That is, the thin portion 304A functions as an intermediate member that connects the flange 304B, the first heat radiator 307A, the second heat radiator 307B, and the frame body 308. The frame body 308 has a thickness larger than that of the meat portion 304A in order to improve the strength of the module case 304.
Reference numeral 309 denotes a distance between the inner wall of the first radiator 307A and the inner wall of the second radiator 307B (hereinafter referred to as an inner wall distance 309). The module case 304 is formed such that the distance 309 between the inner walls is smaller than the thickness 303 of the module primary sealing body 302.
FIGS. 9A to 9D are process diagrams showing a process of inserting the module primary sealing body 302 into the module case 304.
As shown in FIG. 9A, a jig 900 having the same thickness as the inner wall distance 309 is inserted into the module case 304. The jig 900 is fixed in the module case 304 with its upper surface in contact with the first heat radiator 307A and with its lower surface in contact with the second heat radiator 307B. The jig 900 forms a space 901 for inserting the jig 902. The height of the space 901 is formed so that the insertion opening 306 side of the module case 304 is larger than the frame body 308 side in FIG. 9A and gradually becomes smaller toward the frame body 308 side. ing.
Next, as shown in FIG. 9B, the jig 902 is inserted into the space 901 of the jig 900, and the jig 902 is pressed toward the pressing direction B. The jig 902 is formed so as to become narrower toward the tip so as to fit with the space 901 of the jig 900. When the jig 902 is pressed in the pressing direction B, the jig 900 is deformed in the transition direction C, and the module case 304 is pushed and spread by the jig 900. The pressurizing force of the jig 902 is set so that the distance 310 between the inner walls after the module case 304 is pushed and spread becomes larger than the thickness 303 of the module primary sealing body 302.
At this time, the thin portion 304A is formed to be extremely thinner than the cooling body, the flange portion 304B, and the frame 308 that form the first radiator 307A and the second radiator 307B, and only the thin portion 304A is elastically deformed. Become.
Next, as shown in FIG. 9C, the module primary sealing body 302 is inserted into the module case 304.
Next, as shown in FIG. 9D, the jig 900 and the jig 902 are extracted from the module case 304, and the applied pressure for elastically deforming the thin portion 304A is released. At that time, the elastically deformed thin portion 304A exerts an elastic force to return to the distance 309 between the inner walls of the module case 304, and the module primary sealing body 302 is formed by the first radiator 307A and the second radiator 307B. Will be supported and fixed. The module primary sealing body 302 is supported and fixed more firmly because the elastic force from the thin portion 304A acts from both the upper and lower surfaces. The distance between the inner walls of the module case 304 is the same as the thickness 303 of the module primary sealing body 302.
Thereby, the dimensional dispersion | variation in the thickness 303 of the module primary sealing body 302 can be absorbed easily.
Note that the surfaces of the first heat radiating body 307A and the second heat radiating body 307B on the side facing the module primary sealing body 302 are formed so as to be the same surface as the surface on the inside of the module case 304 of the thin portion 304A. Thereby, the jig 900 can be smoothly inserted into the module case 304.
In the present embodiment, an example in which the thin portion 304A is elastically deformed is shown. However, when the module primary sealing body 302 is inserted into the module case 304, the distance between the inner walls 309 of the module case 304 and the thickness of the thin portion 304A may be set so that the thin portion 304A is plastically deformed. Further, when plastically deforming the thin wall portion 304A, it is more desirable to improve the bonding force between the module case 304 and the module primary sealing body 302 by providing the insulating sheet 333 with adhesiveness.
10A is a perspective view of the auxiliary mold body 600, and FIG. 10B is a transparent view of the auxiliary mold body 600. The auxiliary mold body 600 shown in FIG. 10 described below is different in shape from the auxiliary mold body 600 shown in FIGS. 8 and 9, but can be used properly depending on the use environment. For example, in order to improve the vibration resistance of the signal wirings 325U and 325L, the auxiliary mold body 600 shown in FIG. 10 described below is suitable.
In the auxiliary mold body 600, the signal conductor 324 is integrated by insert molding. Here, the signal conductor 324 receives the temperature information of the upper arm side gate electrode terminal 154 and the emitter electrode terminal 155, the upper arm side gate electrode terminal 164 and the emitter electrode terminal 165 (see FIG. 2), and the power semiconductor element. A terminal for transmission is included. In the description of this embodiment, these terminals are collectively referred to as signal terminals 325U and 325L.
The signal conductor 324 forms signal terminals 325U and 325L at one end, and forms element-side signal terminals 326U and 326L at the other end. The element-side signal terminals 326U and 326L are connected to signal pads provided on the surface electrode of the power semiconductor element by, for example, wires. The first sealing portion 601A has a shape extending in a direction crossing the major axis of the shape of the DC positive electrode wiring 315A, the DC negative electrode wiring 319A, or the AC wiring 320 shown in FIG. On the other hand, the second sealing portion 601B has a shape extending in a direction substantially parallel to the major axis of the shape of the DC positive electrode wiring 315A, the DC negative electrode wiring 319A, or the AC wiring 320. The second sealing portion 601B includes a sealing portion for sealing the signal terminal 325U on the upper arm side and a sealing portion for sealing the signal terminal 325L on the lower arm side.
The auxiliary mold body 600 is formed to have a length longer than the entire length of the conductor plates 315 and 316 arranged side by side or the entire length of the conductor plates 319 and 320 arranged side by side. That is, the lengths of the conductor plates 315 and 316 arranged side by side or the lengths of the conductor plates 319 and 320 arranged side by side are within the range of the lateral length of the auxiliary mold body 600.
The first sealing portion 601A has a hollow shape and forms a wiring fitting portion 602A for fitting the DC negative electrode wiring 319A into the hollow. The first sealing portion 601A has a hollow shape and forms a wiring fitting portion 602B for fitting the DC positive electrode wiring 315A into the hollow. Furthermore, the first sealing portion 601A is disposed on the side of the wiring fitting portion 602A, has a hollow shape, and further forms a wiring fitting portion 602C for fitting the AC wiring 320 into the hollow. . Each wiring is positioned by fitting each wiring to these wiring fitting portions 602A to 602C. Thereby, it becomes possible to perform the filling operation of the resin sealing material after firmly fixing each wiring, and the mass productivity is improved.
Moreover, the wiring insulation part 608 protrudes in a direction away from the first sealing part 601A from between the wiring fitting part 602A and the wiring fitting part 602B. Since the plate-shaped wiring insulating portion 608 is interposed between the DC positive electrode wiring 315A and the DC negative electrode wiring 319A, it is possible to arrange the wiring insulating portion 608 so as to reduce the inductance while ensuring insulation.
Further, the first sealing portion 601A is formed with a mold pressing surface 604 that comes into contact with a mold used for resin sealing, and the mold pressing surface 604 prevents resin leakage during resin sealing. A protruding portion 605 for preventing is formed around the outer periphery in the longitudinal direction of the first sealing portion 601. A plurality of protrusions 605 are provided to enhance the resin leakage prevention effect. Furthermore, since the protrusions 605 are also provided in the wiring fitting part 602A and the wiring fitting part 602B, it is possible to prevent the resin sealing material from leaking from the periphery of the DC positive electrode wiring 315A and the DC negative electrode wiring 319A. Here, as the material of the first sealing portion 601A, the second sealing portion 601B, and the projection portion 605, heat that can be expected to have high heat resistance is considered when installed in a mold of about 150 to 180 ° C. A liquid crystal polymer of plastic resin, polybutylene terephthalate (PBT) or polyphenylene sulfide resin (PPS) is desirable.
Also, a plurality of through holes 606 shown in FIG. 10B are provided in the longitudinal direction on the power semiconductor element side in the short direction of the first sealing portion 601A. As a result, the first sealing resin 348 flows into the through-hole 606 and hardens, whereby an anchor effect is exerted, and the auxiliary mold body 600 is firmly held by the first sealing resin 348, and temperature changes and machine Even if stress is applied by mechanical vibration, both do not peel off. It is difficult to peel even if the shape is uneven instead of the through hole. Further, a certain degree of effect can be obtained by applying a polyimide coating agent to the first sealing portion 601A or roughening the surface.
In the sealing step of the first sealing resin 348 in the module primary sealing body 302, first, the auxiliary mold body 600 supporting each wiring is inserted into a mold preheated to about 150 to 180 ° C. In the present embodiment, the auxiliary mold body 600, the DC positive electrode wiring 315A, the DC negative electrode wiring 319A, the AC wiring 320, the conductor plate 315, the conductor plate 316, the conductor plate 318, and the conductor plate 319 are firmly connected to each other. By installing the mold body 600 at a predetermined position, the main circuit and the power semiconductor element are installed at the predetermined position. Therefore, productivity is improved and reliability is improved.
The second sealing portion 601B is formed to extend from the vicinity of the module case 304 to the vicinity of the driver circuit board 22. As a result, when wiring with the driver circuit board 22 through the high-power wiring, the switching control signal can be normally transmitted even when exposed to a high voltage. Further, even if the DC positive wiring 315A, the DC negative wiring 319A, the AC wiring 320, the signal terminal 325U, and the signal terminal 325L protrude from the module case 304 in the same direction, electrical insulation can be ensured and reliability is ensured. it can.
FIG. 11 is an exploded perspective view for explaining the internal structure of the capacitor module 500. The laminated conductor plate 501 is composed of a negative electrode conductor plate 505 and a positive electrode conductor plate 507 formed of a plate-like wide conductor, and an insulating sheet 517 sandwiched between the negative electrode conductor plate 505 and the positive electrode conductor plate 507. As described below, the laminated conductor plate 501 cancels out the magnetic flux with respect to the current flowing through the series circuit 150 of the upper and lower arms of each phase, so that the inductance of the current flowing through the series circuit 150 of the upper and lower arms is reduced. . The laminated conductor plate 501 has a substantially rectangular shape. The negative power supply terminal 508 and the positive power supply terminal 509 are formed in a state where they are raised from one side of the laminated conductor plate 501 in the short direction, and are connected to the positive conductor plate 507 and the negative conductor plate 505, respectively. ing. DC power is supplied to the positive power supply terminal 509 and the negative power supply terminal 508 via the DC connector 138 as described with reference to FIG.
The capacitor terminals 503a to 503c are formed corresponding to the positive electrode terminal 157 (315B) and the negative electrode terminal 158 (319B) of each power module 300 in a state where the capacitor terminals 503a to 503c are raised from one side in the longitudinal direction of the multilayer conductor plate 501. The Further, the capacitor terminals 503d to 503f are raised from the other side in the longitudinal direction of the multilayer conductor plate 501, and correspond to the positive terminal 157 (315B) and the negative terminal 158 (319B) of each power module 301. It is formed. The capacitor terminals 503a to 503f are raised in a direction crossing the main surface of the laminated conductor plate 501. Capacitor terminals 503a to 503c are connected to power modules 300a to 300c, respectively. Capacitor terminals 503d to 503f are connected to power modules 301a to 301c, respectively. A part of the insulating sheet 517 is provided between the negative-side capacitor terminal 504a and the positive-side capacitor terminal 506a constituting the capacitor terminal 503a to ensure insulation. The same applies to the other capacitor terminals 503b to 503f. In the present embodiment, the negative electrode conductor plate 505, the positive electrode conductor plate 507, the battery negative electrode side terminal 508, the battery negative electrode side terminal 509, and the capacitor terminals 503a to 503f are configured by integrally formed metal plates, and the upper and lower arms This has the effect of reducing the inductance with respect to the current flowing through the series circuit 150.
A plurality of capacitor cells 514 are provided on the inner side of the capacitor module 500 below the laminated conductor plate 501. In the present embodiment, eight capacitor cells 514 are arranged in a line along one side in the longitudinal direction of the multilayer conductor plate 501, and another eight capacitor cells 514 are arranged on the other side in the longitudinal direction of the multilayer conductor plate 501. A total of 16 capacitor cells are arranged in a line along the side. The capacitor cells 514 arranged along the longitudinal sides of the multilayer conductor plate 501 are arranged symmetrically with respect to the dotted line AA shown in FIG. Thereby, when the direct current smoothed by the capacitor cell 514 is supplied to the power modules 300a to 300c and the power modules 301a to 301c, the current balance between the capacitor terminals 503a to 503c and the capacitor terminals 503d to 503f is uniform. The inductance of the laminated conductor plate 501 can be reduced. Moreover, since it can prevent that an electric current flows locally in the laminated conductor board 501, a heat balance can be equalized and heat resistance can also be improved.
Since many capacitor cells 514 are arranged in the direction along the flow path, the power module 300 and the power module 301 arranged along the flow path are connected to the series circuit 150 of the U-phase, V-phase, and W-phase upper and lower arms. On the other hand, it tends to be uniform. Further, there is an effect that each capacitor cell 514 can be uniformly cooled by the refrigerant. Further, the current balance between the capacitor terminals 503a to 503c and the capacitor terminals 503d to 503f can be made uniform to reduce the inductance of the multilayer conductor plate 501, and the heat balance is made uniform to improve heat resistance. Can do.
The capacitor cell 514 is a unit structure of the power storage unit of the capacitor module 500, and is a film in which two films each having a metal such as aluminum deposited thereon are stacked and wound, and each of the two metals is used as a positive electrode and a negative electrode. Use a capacitor. The electrode of the capacitor cell 514 is manufactured by spraying a conductor such as tin, with the wound shaft surfaces serving as a positive electrode and a negative electrode, respectively.
The capacitor case 502 includes a storage portion 511 for storing the capacitor cell 514, and the storage portion 511 has a substantially rectangular upper surface and lower surface shown in the drawing. The capacitor case 502 is provided with fixing means for fixing the capacitor module 500 to the flow path forming body 12, for example, holes 520a to 520d for allowing a screw to pass therethrough. The bottom surface portion 513 of the storage portion 511 has a smooth uneven shape or corrugated shape so as to match the surface shape of the cylindrical capacitor cell 514. Thereby, it becomes easy to position the module in which the laminated conductor plate 501 and the capacitor cell 514 are connected to the capacitor case 502. After the multilayer conductor plate 501 and the capacitor cell 514 are accommodated in the capacitor case 502, the multilayer conductor plate 501 is covered except for the capacitor terminals 503a to 503f, the negative power supply terminal 508, and the positive power supply terminal 509. In this way, the capacitor case 502 is filled with a filler (not shown). Since the bottom surface portion 513 has a corrugated shape in accordance with the shape of the capacitor cell 514, the capacitor cell 514 can be prevented from being displaced from a predetermined position when the filler is filled in the capacitor case 502.
Further, the capacitor cell 514 generates heat due to a ripple current at the time of switching due to an electric resistance of a metal thin film and an internal conductor deposited on the internal film. Therefore, in order to easily release the heat of the capacitor cell 514 through the capacitor case 502, the capacitor cell 514 is molded with a filler. Furthermore, the moisture resistance of the capacitor cell 514 can be improved by using a resin filler. In the present embodiment, the flow path is provided along the longitudinal direction of the storage portion 511 of the capacitor module 500, and the cooling efficiency is improved. Furthermore, in the present embodiment, the capacitor module 500 is disposed so that the side wall forming the side in the longitudinal direction of the storage portion 511 is sandwiched between the flow paths 19, so that the capacitor module 500 can be cooled efficiently. In addition, the capacitor cell 514 is disposed so that one of the electrode surfaces of the capacitor cell 514 is opposed to the inner wall forming the side in the longitudinal direction of the storage portion 511. As a result, heat is easily transferred in the direction of the winding axis of the film, so that heat easily escapes to the capacitor case 502 via the electrode surface of the capacitor cell 514.
In the following description, the DC negative terminal 315B and the positive terminal 157 shown in FIG. 2 are the same. Further, the DC positive terminal 319B and the negative terminal 158 shown in FIG. 2 are the same. FIG. 12 is an external perspective view in which the power module 300, the capacitor module 500 and the bus bar assembly 800 are assembled to the flow path forming body 12. FIG. 13 is an enlarged view of a portion A in FIG. 12 and 13, the DC negative terminal 315B (157), the DC positive terminal 319B (158), the AC terminal 321 (159), and the second sealing portion 601B extend toward the lid in the longitudinal direction of the housing 10. ing. The area of the current path of the DC negative terminal 315B (157) and the DC positive terminal 319B (158) is much smaller than the area of the current path of the laminated conductor plate 501. Therefore, when the current flows from the laminated conductor plate 501 to the DC negative terminal 315B (157) and the DC positive terminal 319B (158), the area of the current path changes greatly. That is, the current concentrates on the DC negative terminal 315B (157) and the DC positive terminal 319B (158). Further, when the DC negative terminal 315B (157) and the DC positive terminal 319B (158) protrude in a direction crossing the laminated conductor plate 501, in other words, the DC negative terminal 315B (157) and the DC positive terminal 319B (158) are stacked. If the conductor plate 501 is in a twisted relationship, a new connection conductor is required, which may reduce productivity and increase costs.
Therefore, in the present embodiment, the negative-side capacitor terminal 504a has a rising portion that rises from the laminated conductor plate 501, and has a connection portion 542 at the tip thereof. Further, the positive electrode side capacitor terminal 506a has a rising portion rising from the laminated conductor plate 501, and has a connecting portion 545 at the tip thereof. A DC positive terminal 319B (158) and a DC negative terminal 315B (157) of the power module 300 are connected between the connecting portion 542 and the connecting portion 545. Accordingly, since the capacitor terminals 504a and 506a form a laminated structure through the insulating sheet until just before the connection portions 542 and 545, the inductance of the wiring portion of the capacitor terminals 504a and 506a where current concentrates can be reduced. Furthermore, the tip of the DC positive terminal 319B (158) and the side of the connecting portion 542 are connected by welding, and similarly, the tip of the DC negative terminal 315B (157) and the side of the connecting portion 545 are connected by welding. . For this reason, productivity can be improved in addition to characteristic improvement by low inductance.
The tip of AC terminal 321 (159) of power module 300 is connected to the tip of AC bus bar 802a by welding. In a production facility for welding, making the welding machine movable in a plurality of directions with respect to an object to be welded leads to a complicated production facility, which is not preferable from the viewpoint of productivity and cost. Therefore, in the present embodiment, the welding location of the AC terminal 321 (159) and the welding location of the DC positive electrode terminal 319B (158) are arranged in a straight line along the longitudinal side of the flow path forming body 12. Thereby, it is possible to perform a plurality of weldings while moving the welding machine in one direction, and productivity is improved.
Further, as shown in FIGS. 4 and 12, the plurality of power modules 300 a to 300 c are arranged in a straight line along the side in the longitudinal direction of the flow path forming body 12. Thereby, when welding the several power module 300a-300c, productivity can be improved further.
FIG. 14 is an exploded perspective view of the flow path forming body 12 and the bus bar assembly 800 in which the power module 300 and the capacitor module 500 are assembled. FIG. 15 is an external perspective view of the bus bar assembly 800 excluding the holding member 803. 14 and 15, a bus bar assembly 800 includes a holding member 803 for holding and fixing the first and second AC bus bars arranged on both sides, and a first AC bus bar 802a provided on both sides. To 802f and second AC bus bars 804a to 804f. The bus bar assembly 800 is further provided with a current sensor 180 for detecting an alternating current flowing through first and second alternating current bus bars 802 and 804 provided on both sides. The first and second AC bus bars 802 and 804 provided on both sides are each made of a wide conductor, and the first AC bus bars 802a to 802f on both sides to the installation location of the current sensor 180a or the current sensor 180b are: The wide surface is disposed so as to be substantially perpendicular to the main surface of the multilayer conductor plate 501 of the capacitor module 500. The first AC bus bars 802a to 802f are each bent at a substantially right angle before the through hole of the current sensor 180a or 180b, so that the wide surfaces of these AC bus bars are substantially parallel to the main surface of the laminated conductor plate 501. After passing through the holes of current sensor 180a and current sensor 180b, they are connected to second AC bus bars 804a to 804f. Most of the second AC bus bars 804a to 804f have a wide surface substantially perpendicular to the main surface of the laminated conductor plate 501 of the capacitor module 500, that is, a state where the narrow surface of the AC bus bar faces the vertical direction of the power converter. doing. As shown in FIG. 15, the first AC bus bars 802a to 802f pass through the holes of the current sensor 180a and the current sensor 180b, and then are connected to the connection portions 805a to 805f (connection portion 805d) formed in the first AC bus bars 802a to 802f. ˜805f are not shown) and are connected to the second AC bus bars 804a to 804f.
As described above, the second AC bus bars 804a to 804f are bent at substantially right angles toward the capacitor module 500 in the vicinity of the connection portions 805a to 805f. Thus, the main surfaces of the second AC bus bars 804a to 804f are formed to be substantially perpendicular to the main surface of the multilayer conductor plate 501 of the capacitor module 500. Further, the second AC bus bars 804a to 804f are directed from the vicinity of the current sensor 180a or the current sensor 180b toward one side 12a in the short direction of the flow path forming body 12, as shown in FIGS. It is extended and formed so as to cross the side 12a. That is, the second AC bus bars 804a to 804f are formed so as to cross the side 12a with the main surfaces of the plurality of second AC bus bars 804a to 804f facing each other.
Since the AC bus bars 802a, 802b, 802d, and 802e are arranged on both sides along the flow paths arranged on both inner sides of the housing 10, the overall size of the apparatus can be reduced. Further, since the narrow surfaces of the wide conductors are arranged so as to face the vertical direction of the device, the space occupied by the first AC bus bar 802 and the second AC bus bar 804 can be reduced, and the overall size of the device can be reduced. . Furthermore, by projecting the plurality of AC bus bars from the one surface side of the flow path forming body 12, it is easy to route the wiring outside the power converter 200, and the productivity is improved.
As shown in FIG. 14, the first AC bus bars 802a to 802f, the current sensors 180a to 180b, and the second AC bus bars 804a to 804f are held and insulated by a holding member 803 made of resin. By this holding member 803, the second AC bus bars 804 a to 804 f improve the insulation between the metal flow path forming body 12 and the housing 10.
The bus bar assembly 800 has a structure that is fixed to the flow path forming body 12 by a holding member 803. Even if heat is transmitted to the housing 10 from the outside, the temperature rise of the flow path forming body 12 in which the flow path of the cooling medium is formed is suppressed. By fixing the bus bar assembly 800 to the flow path forming body 12, not only the temperature rise of the bus bar assembly 800 can be suppressed, but also the temperature increase of the current sensor 180 held in the bus bar assembly 800 can be suppressed. The current sensor 180 has heat-sensitive characteristics, and the above structure can improve the reliability of the current sensors 180a to 180b. Further, when the power conversion device is fixed to the transmission as in this embodiment, not only heat is transmitted to the housing 10 from the transmission TM side, but also heat is transmitted from the motor generator side through the second AC bus bars 804a to 804f. Is transmitted. These heats can be blocked by the flow path forming body 12, or the heat can be released to the refrigerant, the temperature rise of the current sensors 180a to 180b can be suppressed, and the reliability can be improved.
As shown in FIG. 14, the holding member 803 includes a support member 807a and a support member 807b for supporting the driver circuit board 22 shown in FIG. A plurality of support members 807a are provided and are formed along one side of the flow path forming body 12 in the longitudinal direction. Further, a plurality of support members 807 b are provided and are formed side by side along the other side in the longitudinal direction of the flow path forming body 12. Screw holes for fixing the driver circuit board 22 are formed at the distal ends of the support member 807a and the support member 807b.
Furthermore, the holding member 803 has a protrusion 806a and a protrusion 806b that extend upward from locations where the current sensor 180a and the current sensor 180b are disposed. The protrusion 806a and the protrusion 806b are configured to penetrate the current sensor 180a and the current sensor 180b, respectively. As illustrated in FIG. 15, the current sensor 180 a and the current sensor 180 b include a signal line 182 a and a signal line 182 b extending in the arrangement direction of the driver circuit board 22. The signal line 182a and the signal line 182b are joined to the wiring pattern of the driver circuit board 22 by solder. In the present embodiment, the holding member 803, the support members 807a to 807b, and the protrusions 806a to 806b are integrally formed of resin.
As a result, the holding member 803 has a function of positioning the current sensor 180 and the driver circuit board 22, so that assembly and solder connection work between the signal line 182 a and the driver circuit board 22 are facilitated. Further, by providing the holding member 803 with a mechanism for holding the current sensor 180 and the driver circuit board 22, the number of components as the whole power conversion device can be reduced.
In the present embodiment, since power conversion device 200 is fixed to housing 10 provided in transmission TM, it is greatly affected by vibration from transmission TM. Therefore, the holding member 803 is provided with a support member 808 for supporting the vicinity of the center portion of the driver circuit board 22 to reduce the influence of vibration applied to the driver circuit board 22. For example, by supporting the center portion of the driver circuit board 22 by the support member 808, the resonance frequency of the driver circuit board 22 can be made higher than the frequency of vibration transmitted from the transmission TM, and the transmission applied to the driver circuit board 22 The influence of TM vibration can be reduced. The holding member 803 of the bus bar assembly 800 is fixed to the flow path forming body 12 with screws.
In addition, the holding member 803 is provided with a bracket 809 for fixing one end of the auxiliary power module 350. As shown in FIG. 4, the auxiliary power module 350 is disposed in the cooling unit 407, so that the other end of the auxiliary power module 350 is fixed to the cooling unit 407. Thereby, the influence of vibration applied to the auxiliary power module 350 can be reduced, and the number of parts for fixing can be reduced.
FIG. 16 is an external perspective view of a state in which the power module, the capacitor module, the bus bar assembly 800, and the auxiliary power module 350 are assembled to the flow path forming body 12. The current sensor 180 cannot be used as a sensor at a temperature of about 100 ° C. or higher. In an in-vehicle power converter, the environment in which it is used is extremely harsh and may become high temperature, and protecting the current sensor 180 from heat is one of the important issues. In particular, in this embodiment, since power conversion device 200 is mounted on transmission TM, it is important to protect current sensor 180 from the influence of heat generated from transmission TM.
Therefore, in the present embodiment, the current sensor 180a and the current sensor 180b are disposed on the opposite side of the transmission TM with the flow path forming body 12 interposed therebetween. Thereby, it is difficult for the heat generated by the transmission TM to be transmitted to the current sensor, and the temperature increase of the current sensor can be suppressed. Furthermore, the second AC bus bars 804a to 804f are formed so as to cross the third flow path 19c shown in FIG. The current sensor 180a and the current sensor 180b are disposed closer to the AC terminal 321 (159) of the power module than the second AC bus bars 804a to 804f that cross the third flow path portion 19c. As a result, the second AC bus bars 804a to 804f are indirectly cooled by the refrigerant, and heat transmitted from the AC bus bar to the current sensor and further to the semiconductor chip in the power module can be relieved, thereby improving the reliability.
A flow direction 810 shown in FIG. 16 indicates the flow direction of the refrigerant flowing through the third flow path 19c shown in FIG. The flow direction 811 indicates the flow direction of the refrigerant flowing through the fourth flow path 19d shown in FIG. Similarly, the flow direction 812 indicates the flow direction of the refrigerant flowing through the second flow path 19b shown in FIG. In the present embodiment, the current sensor 180 a and the current sensor 180 b are arranged so that the projection parts of the current sensor 180 a and the current sensor 180 b are surrounded by the projection part of the flow path 19 when projected from above the power conversion device 200. Is done. This further protects the current sensor from heat from the transmission TM.
FIG. 17 is a perspective view showing a state in which the control circuit board 20 and the metal base plate 11 are separated to help understanding. As shown in FIG. 16, the current sensor 180 is disposed above the capacitor module 500. The driver circuit board 22 is disposed above the current sensor 180 of FIG. 16, and is further supported by support members 807a and 807b provided in the bus bar assembly 800 shown in FIG. The metal base plate 11 is disposed above the driver circuit board 22 and is supported by a plurality of support members 15 erected from the flow path forming body 12 in this embodiment. The control circuit board 20 is disposed above the metal base plate 11 and is fixed to the metal base plate 11.
Since the current sensor 180, the driver circuit board 22, and the control circuit board 20 are hierarchically arranged in the height direction, and the control circuit board 20 is arranged at the farthest place from the power modules 300 and 301 of the high voltage system, the switching noise Etc. can suppress mixing. Furthermore, the metal base plate 11 is electrically connected to the flow path forming body 12 that is electrically connected to the ground. The metal base plate 11 reduces noise mixed from the driver circuit board 22 into the control circuit board 20.
If a wiring connector is used when the current sensor 180 and the driver circuit board 22 are electrically connected, it is desirable to prevent the complexity of the connection process and connection errors. In FIG. 17, a first hole 24 and a second hole 26 that penetrate the driver circuit board 22 are formed in the driver circuit board 22. In addition, the signal terminal 325U and the signal terminal 325L of the power module 300 are inserted into the first hole 24, and the signal terminal 325U and the signal terminal 325L are joined to the wiring pattern of the driver circuit board 22 by soldering. Further, the signal line 182 of the current sensor 180 is inserted into the second hole 26, and the signal line 182 is joined to the wiring pattern of the driver circuit board 22 by solder. Note that solder bonding is performed from the surface side of the driver circuit board 22 opposite to the surface facing the flow path forming body 12.
Thereby, since a signal line can be connected without using a wiring connector, productivity can be improved. Moreover, productivity can be further improved by joining the signal terminal 325 of the power module 300 and the signal line 182 of the current sensor 180 by soldering from the same direction. Further, by providing the driver circuit board 22 with the first hole 24 for penetrating the signal terminal 325 and the second hole 26 for penetrating the signal line 182, it is possible to reduce the risk of connection mistakes. .
In addition, the driver circuit board 22 of the present embodiment has a drive circuit (not shown) such as a driver IC chip mounted on the side facing the flow path forming body 12. Thus, the heat of solder bonding is suppressed from being transmitted to the driver IC chip or the like, and damage to the driver IC chip or the like due to solder bonding is prevented. In addition, since a high-profile component such as a transformer mounted on the driver circuit board 22 is disposed in the space between the capacitor module 500 and the driver circuit board 22, the entire power conversion device 200 can be reduced in height. Is possible.
In the present embodiment, the refrigerant flowing through the flow path 19 cools the power modules 300 and 301 inserted and fixed in the flow path 19 and cools the capacitor module 500. Further, it is desirable to cool the auxiliary power module 350 in order to suppress a temperature rise due to heat generation. Since the portion that can be cooled in the housing 10 is limited, a cooling method and a cooling structure are required.
Therefore, in the present embodiment, the heat dissipating surface formed by the metal base of the auxiliary power module 350 is disposed so as to face the cooling unit 407 shown in FIG. The cooling unit 407 in FIG. 4 is provided to cool the auxiliary power module 350. The back side of the cooling unit 407 is shown in FIG. A cross-sectional view of the cooling unit 407 is shown in FIG. In FIGS. 4, 5, and 19, the auxiliary power module 350 is fixed such that the heat radiating surface thereof is in contact with the outer peripheral surface of the cooling unit 407. Since the cooling unit 407 is formed above the inlet pipe 13, the refrigerant flowing in from below can collide with the inner wall of the cooling unit 407 and efficiently take heat from the auxiliary power module 350. The refrigerant flowing in from the inlet pipe 13 shown by the broken line in FIG. 19 collides with the upper surface of the refrigerant reservoir 19f formed inside the cooling unit 407, and the flow direction is changed. At this time, the cooling unit 407 is deprived of heat. The refrigerant whose direction has been changed flows from the flow path 19a into the flow path 19b shown in FIGS. 4 and 5, and cools the power modules 300 and 301. The refrigerant that has cooled the power module 301 flows into the flow path 19e and is discharged from the outlet pipe 14 indicated by a broken line. A refrigerant reservoir 19g is formed in the upper part of the flow path 19e, and the cooling unit 407 is cooled by the refrigerant in the refrigerant reservoir 19g. In order to set the fluid resistance of the flow path to an appropriate state, the refrigerant reservoir 19f on the inflow side is made larger than the refrigerant reservoir 19g on the outlet side. With such a structure, the auxiliary power module 350 can be efficiently cooled.
FIG. 18 is a cross-sectional view of the power conversion device 200 as viewed from the direction C on the surface indicated by the broken line B in FIG. The flange 304B provided in the module case 304 is pressed against the opening of the flow path of the flow path forming body 12, and the air tightness of the flow path 19 can be improved by pressing the module case 304 against the flow path forming body 12. it can. In order to improve the cooling efficiency of the power module 300, it is necessary to allow the refrigerant in the flow path 19 to flow through the region where the fins 305 are formed. In the module case 304, the fin 305 is not formed in the lower part of the module case 304 in order to secure the space of the thin portion 304A. Therefore, the lower cover 420 is formed so that the lower portion of the module case 304 is fitted into the recess 430 formed in the lower cover 420. Thereby, it can prevent that a refrigerant | coolant flows into the space in which the cooling fin is not formed.
FIG. 20A is a perspective view of the module case 370 according to the second embodiment. FIG. 20B is a cross-sectional view of the module case 370 viewed from the cross-section A of FIG. The configuration denoted by the same drawing number as the above-described embodiment (FIG. 8B) has the same function as the configuration of the above-described embodiment.
The thin portion 304A is formed so as to surround the first heat radiator 307A and is extremely thinner than the first heat radiator 307A, the flange portion 304B, and the frame body 308. Therefore, only the thin portion 304A can be locally elastically deformed. On the other hand, the fixing member 311 formed surrounding the second radiator 307B is formed thicker than the thin portion 304A. The thin portion 304A functions as an intermediate member that connects the first heat radiator 307A and the frame body 308, and the fixing member 311 functions as an intermediate member that connects the second heat radiator 307B and the frame body 308. Further, the fixing member 311 is formed so as to be flush with the inner wall surface of the second radiator 307B.
FIGS. 21A and 21B are process diagrams showing a process of inserting the module primary sealing body 302 into the module case 370. The inner wall distance 312 is formed to be smaller than the thickness 303 of the module primary sealing body 302 shown in FIG.
The process shown in FIG. 21A is the same process as that in FIG. However, only the thin portion 304A is elastically deformed by the jig 902, and the fixing member 311 is not deformed. Then, as shown in FIG. 21D, the jig 900 and the jig 902 are extracted from the module case 304, and the applied pressure for elastically deforming the thin portion 304A is released. At that time, the elastically deformed thin portion 304A exerts an elastic force to return to the distance 309 between the inner walls of the module case 304, and the module primary sealing body 302 causes the first heat radiating body 307A and the second heat radiating body 307B to move. It will be supported and fixed by the cooling body to be formed. The module primary sealing body 302 is supported and fixed by the elastic force from the thin-walled portion 304A on the upper surface side and the fixing member 311 that holds the elastic force.
When the signal terminals 325U and 325L of the power module 300 are connected to the driver circuit board 22, the positioning of the module primary sealing body 302 and the module case 370 is important, and the module primary sealing body 302 and the module case are improved for improving the productivity. It is required that 370 be assembled with high accuracy. Therefore, by using the module case 370 as in the present embodiment, the effect of absorbing the dimensional variation due to the displacement of the first radiator 307A and the second radiator 307B is reduced by half, but the fixing member 311 and the second radiator The module primary sealing body 302 can be mounted on the module case 370 with high positioning accuracy by using the ground contact surface of the body 307B as a reference plane.
In the present embodiment, an example in which the thin portion 304A is elastically deformed is shown. However, when the module primary sealing body 302 is inserted into the module case 304, the distance 309 between the inner walls of the module case 304 and the thickness of the thin portion 304A may be set so that the thin portion 304A is plastically deformed. Further, when plastically deforming the thin wall portion 304A, it is more desirable to improve the bonding force between the module case 304 and the module primary sealing body 302 by providing the insulating sheet 333 with adhesiveness.
FIG. 22A is a perspective view of a module case 371 according to the third embodiment. FIG. 22B is a cross-sectional view of the module case 371 viewed from the cross-section A of FIG. 23A to 23D are process diagrams showing a process of inserting the module primary sealing body 302 into the module case 371. The configuration given the same drawing number as the above-described embodiment (FIG. 20) has the same function as the configuration of the above-described embodiment.
Concave portions 313 and 314 are formed in the first radiator 307A surrounded by the thin portion 304A. As shown in FIG. 23A, a jig 903 is inserted into the recesses 313 and 314. The jig 903 generates an upward pulling force so as to elastically deform the thin portion 304A and lift the first heat radiator 307A. Then, as shown in FIGS. 23B to 23D, a process for inserting the module primary sealing body 302 and supporting and fixing the module primary sealing body 302 to the module case 371 is performed.
This eliminates the need for the jigs 900 and 902 used in the first and second embodiments, leading to improved productivity and cost reduction. Further, when a jig is inserted into the case when it is spread out, it is necessary to provide a space for the jig insertion portion. However, by providing the recesses 313 and 314 on the outer surface side of the module case 371, the inside of the module case 371 Since it is not necessary to provide a space for inserting the jigs 900 and 902, the module case 371 can be downsized.
The recess 314 is formed diagonally to the recess 313 in the first radiator 307A. Thereby, the force pulling the first heat radiating body 307A is transmitted in a well-balanced manner, and the parallelism between the module case 371 and the module primary sealing body 302 can be increased.
In the present embodiment, the thin portion 304A is formed only on the first radiator 307A, but the thin portion 304A may be formed on both the first radiator 307A and the second radiator 307B. Applicable. That is, the recesses 313 and 314 are formed in both the first heat radiator 307A and the second heat radiator 307B.
FIG. 24A is a perspective view of a module case 372 according to the fourth embodiment. FIG. 24B is a diagram showing the inside of the module case 372 as seen from the direction of the arrow B. FIG. 24C is a cross-sectional view of the module case 371 as viewed from the cross-section A of FIG.
The structure of the module case according to the second and third embodiments is effective for positioning in the thickness direction. However, the connection position between the module sealing body 302 and the driver circuit board 22 needs to be positioned in the thickness direction of the module sealing body 302 and in the direction perpendicular to the thickness direction.
Therefore, as shown in FIG. 24C, the first protrusion 334 and the second protrusion 335 are formed on the inner wall of the module case 372. For example, the first protrusion 334 and the second protrusion 335 are formed on the inner wall side of the module case 372 of the second heat radiator 307B. The first protrusion 334 and the second protrusion 335 are formed such that the distance 336 between them is substantially the same as the width 337 of the module sealing body 302. Here, the distance 336 and the width 337 are substantially equal to each other so that the module sealing body 302 can be inserted into the first protrusion 334 and the second protrusion 335 and the module sealing body 302 can be slid. That's it. Thereby, the positioning accuracy of the module sealing body 302 can be improved, leading to an improvement in productivity.
In addition, a groove 338 is formed at the ends of the first protrusion 334 and the second protrusion 335. The groove 338 has a function of positioning a jig for pushing up the second heat radiating body 307B. As a result, further improvement in productivity can be expected.
FIG. 25A is a perspective view of a module primary sealing body 380 according to the fifth embodiment. FIG. 25B is a cross-sectional view of the module primary sealing body 380 taken through the line A in FIG. FIG. 26A is a perspective view of a module case 374 according to the fifth embodiment. FIG. 26B is a cross-sectional view of the module case 373 viewed from the cross-section A of FIG. The configuration denoted by the same drawing number as the above-described embodiment (FIG. 8B) has the same function as the configuration of the above-described embodiment.
The module primary sealing body 380 is provided with a first protrusion 339 and a second protrusion 340 on the end opposite to the side from which the AC terminal 321 protrudes. The first protrusion 339 and the second protrusion 340 constitute a part of the first sealing resin 348. Further, the corners 342 of the first protrusion 339 and the second protrusion 340 have a shape having a smooth R. Thereby, when it contacts with the module case 373 mentioned later, the corner | angular part 342 of the 1st protrusion part 339 and the 2nd protrusion part 340 becomes difficult to chip, and the heat conduction of the thermal radiation surface 343 of the module primary sealing body 380 is reduced. To prevent that. The first protrusion 339 and the second protrusion 340 are formed such that the distance 341 between the vertex of the first protrusion 339 and the vertex of the second protrusion 340 is larger than the distance 344 between the inner walls shown in FIG. Is done.
Further, as shown in FIG. 26B, a first projecting surface 345A is formed on the inner wall side of the module case 374. Further, a second projecting surface 345B is formed on the inner wall side of the module case 374 via the first projecting surface 345A and a space. Since the first projecting surface 345A is formed integrally with the first heat radiating body 307A and the second projecting surface 345B is formed integrally with the second heat radiating body 307B, high thermal conductivity is maintained.
FIGS. 27A to 27C are process diagrams showing a process of inserting the module primary sealing body 380 into the module case 374.
As shown in FIG. 27A, when the jig 902 is inserted into the space 901 of the jig 900 and the jig 902 is pressed in the pressing direction B, the jig 900 is moved in the transition direction C. The module case 374 is pushed and spread by the jig 900. The pressurizing force of the jig 902 is set so that the distance 310 between the inner walls after the module case 374 is spread out is larger than the distance 341 between the vertex of the first protrusion 339 and the vertex of the second protrusion 340. .
Next, as shown in FIG. 27B, the module primary sealing body 380 is inserted into the module case 374. Insulating sheets 333 are disposed on both surfaces of the module primary sealing body 380, respectively. Here, the first protrusion 339 and the second protrusion 340 are in contact with the first protrusion 345A and the second protrusion 345B, respectively. Thereby, it can prevent that the module case 374 contacts the insulating sheet 333 and the position of the said insulating sheet 333 shifts | deviates.
Next, as shown in FIG. 27C, the jig 900 and the jig 902 are extracted from the module case 374, and the applied pressure for elastically deforming the thin portion 304A is released. At that time, the elastically deformed thin portion 304A works to return to the distance 344 between the inner walls of the module case 304, and the module primary sealing body 380 is formed by the first radiator 307A and the second radiator 307B. Will be supported and fixed.
In the present embodiment, the process using the jigs 900 and 902 is shown as shown in FIG. 27A. However, this process may be omitted. That is, the first protrusion 339 and the second protrusion 340 are formed to be tapered as shown in FIG. Then, the first projecting portion 339 and the second projecting portion 340 are brought into contact with the first projecting surface 345A and the second projecting surface 345B, respectively, and pressed in the direction in which the module primary sealing body 380 itself is inserted into the module case 374, The first radiator 307A and the second radiator 307B can be pushed up. Thereby, it is not necessary to use the jigs 900 and 902, the productivity is improved, and the cost is reduced.
Further, in the module case 374 of the present embodiment, the thin portion 304A surrounding the second heat radiating body 307B may be used as the fixing member 311 described in the second embodiment. In that case, the above-described object can be achieved with only the first protrusion 339 without providing the second protrusion 340.
FIG. 28A is a perspective view of a module primary sealing body 381 according to the sixth embodiment. FIG. 28B is a cross-sectional view of the module primary sealing body 381 passing through the line A in FIG. FIG. 29A is a perspective view of a module case 375 according to the sixth embodiment. FIG. 29B is a front view seen from the formation surface of the fin 305 of the module case 375. FIG.29 (c) is sectional drawing of the module case 375 seen from the cross section A of Fig.29 (a). The configuration given the same drawing number as the above-described embodiment (FIGS. 25 and 26) has the same function as the configuration of the above-described embodiment.
As shown in FIGS. 28A and 28B, the module primary sealing body 381 forms a first recess 346A on one surface and a second recess 346B on the other surface. The first recess 346A and the second recess 346B are formed by raising the first sealing resin 348 on the end side of the module primary sealing body 381. A portion where the first sealing resin 348 is raised is referred to as a convex portion 364. The convex portion 364 is formed so that the corner becomes gentle so that the corner is not cut. The exposed surface 318A of the conductor plate 318 and the exposed surface 319A of the conductor plate 319 are exposed at the bottom of the first recess 346A. On the other hand, as shown in FIG. 28B, the exposed surface 315B of the conductor plate 315 and the exposed surface 316B of the conductor plate 316 are exposed at the bottom of the second recess 346B.
As shown in FIG. 28A, when projected from the vertical direction of the exposed surface 318A of the conductor plate 318, the first recess 346A is the first on the side close to the AC terminal 321 in the projection of the first recess 346A. The side 347 is formed so that the length thereof is longer than the length of the second side 349 facing the first side 347. That is, the projection part of the first recess 346A has a trapezoidal shape as shown in FIG. The same configuration of the second recess 346B is made.
Further, as shown in FIG. 28B, the exposed surface 315B and the exposed surface 316B are covered with a single insulating sheet 333. The exposed surface 318A and the exposed surface 319A are covered with a single insulating sheet 333. The insulating sheet 333 has a shape that can be stored in the bottom of the first recess 346A or the bottom of the second recess 346B. For example, since the exposed portion of the conductor plate is covered in a trapezoidal shape so as to have the same shape as the first recess 346A and the second recess 346B, an arc discharge is generated in the module case 375 described later. It is possible not to provide a void that would be lost.
As shown in FIGS. 29A and 29B, in the module case 375 of this embodiment, the length of the side closer to the insertion port 306 is larger than the length of the side forming the bottom surface of the module case 375. Formed to be. In addition, as shown in FIG. 29B, when viewed from the formation surface side of the fin 305, the first heat radiating plate 307 </ b> A and the second heat radiating plate 307 </ b> B are provided with the first recess 346 </ b> A and the second radiating plate 346 </ b> A of the module primary sealing body 381. It has the same shape as the recess 346B. That is, the first heat radiating plate 307A is formed such that the first side 352 on the side close to the flange 304B is longer than the second side 353 on the side close to the bottom surface of the joule case 375. The second heat radiating plate 307B has the same shape. As shown in FIG. 29C, the joule case 375 is configured such that the distance 344 between the inner walls is smaller than the height of the convex portion 364 shown in FIG.
FIGS. 30A to 30D are process diagrams illustrating a process of inserting the module primary sealing body 381 into the module case 375. FIG. 30B is a cross-sectional view taken along the line A in FIG. FIG. 30D is a cross-sectional view taken along the line A in FIG.
As shown in FIGS. 30A and 30B, when the module primary sealing body 381 is inserted into the module case 375, the convex portion 364 causes the space between the first radiator 307A and the second radiator 307B. It is pushed out. The distance between the first radiator 307A and the second radiator 307B is substantially the same as the height of the convex portion 364. Insulating sheets 333 are respectively disposed on both surfaces of the module primary sealing body 381. Here, the convex portion 364 contacts the first projecting surface 345A and the second projecting surface 345B. Thereby, it can prevent that the module case 375 contacts the insulating sheet 333 and the position of the said insulating sheet 333 shifts | deviates.
Further, as shown in FIGS. 30A and 30B, the second side 353 of the convex portion 364 is inserted into the module case 375 in a state where it is in contact with the first side 352 of the first heat radiator 307A. . Thereby, the first heat radiator 307A is lifted in parallel to the module primary sealing body 381. Therefore, it is possible to prevent the first projecting surface 345A of the module case 375 from coming into contact with the first recess 346A of the module primary seal 381 while the module primary seal 381 is being inserted into the module case 375. Can do. Further, the thin portion 304A surrounding the first heat radiator 307A is locally deformed, so that stress is concentrated, and breakage such as cracking of the thin portion 304A can be prevented. The second radiator 307B has the same configuration and operational effects.
30C and 30D, the first projecting surface 345A of the module case 375 is fitted into the first recess 346A of the module primary sealing body 381. The distance between the first protrusion surface 345A and the second protrusion surface 345B shown in FIGS. 30C and 30D is substantially the same as the distance between the bottom surface of the first recess 346A and the bottom surface of the second recess 346B. Accordingly, the first projecting surface 345A and the first recess 346A are close to each other and thermally connected to improve the heat dissipation of the semiconductor element.
By using the power module of the present embodiment, the number of jigs for manufacturing can be reduced, and the productivity can be improved. Further, the positioning accuracy of terminals such as the signal terminal 325U can be improved.
The fins 305 of the module cases 370 to 375 according to the first to sixth embodiments described so far have a pin shape. However, the fin 305 can be a straight fin. By using straight fins, the rigidity of the first heat radiator 307A and the second heat radiator 307B is increased. Thereby, the reliability of the manufacturing process in the case of inserting the module primary sealing body can be improved by expanding the first radiator 307A and the second radiator 307B as in the present embodiment.
300 Power module 302 Module primary sealing body 303 Thickness 304 Module case 304A Thin portion 304B Flange 305 Fin 306 Insertion port 307A First heat radiator 307B Second heat radiator 308 Frame bodies 309, 310, 312 Distance between inner walls 311 Fixing member 313 , 314 Recessed parts 315, 316, 318, 319 Conductor plates 315B, 316B, 318A, 319A Exposed surface 321 AC terminal 325L, 325U Signal terminal 333 Insulating sheet 334 First protrusion 335 Second protrusion 336, 341 Distance 337 Width 338 Groove 339 First protrusion 340 Second protrusion 342 Corner 343 Heat radiation surface 345A First protrusion surface 345B Second protrusion surface 346A First recess 346B Second recess 347, 352 First side 348 First sealing resin 351 Second sealing Resin 353 second side 364 convex 370, 371, 372, 373, 374, 375 Module case 380, 381 Module primary sealing body
A sealing element comprising: a semiconductor element; a first conductor plate connected to one electrode surface of the semiconductor element via solder; and a sealing material for sealing the semiconductor element and the first conductor plate. Body,
A case for storing the sealing body,
The case includes a first heat radiating plate facing one surface of the sealing body, a second heat radiating plate facing the other surface opposite to the one surface of the sealing body, and the first heat radiating plate. A plate and an intermediate member connecting the second heat radiating plate,
The intermediate member is provided with a first thin portion that is thinner than the thickness of the first heat radiating plate, is more elastically deformed than the first heat radiating plate, and is formed so as to surround the first heat radiating plate. Have
The sealing body is a power module that is pressed and fixed to the second heat radiating plate via the first heat radiating plate by an elastic force generated in the first thin portion.
The power module according to claim 1,
The power module is formed such that a surface of the first heat radiating plate facing the sealing body is flush with a surface of the first thin portion on the case inner side.
A power module in which pin fins are formed on the first heat radiating plate and the second heat radiating plate.
A power module in which linear fins are formed on the first heat radiating plate and the second heat radiating plate.
The intermediate member is provided with a second thin portion having a thickness smaller than that of the second heat radiating plate and being more easily elastically deformed than the second heat radiating plate, and further surrounding the second heat radiating plate. Have
The sealing body is pressed against the second heat radiating plate via the first heat radiating plate by the elastic force generated in the first thin portion, and the second heat radiating plate is pressed by the elastic force generated in the second thin portion. power module to be fixed by being pressed in the first release heat plate via.
The intermediate member is formed to have a thickness larger than the thickness of the first thin portion and to surround the second heat radiating plate, and the first heat generated via the first heat radiating plate and the sealing body. A power module that forms a holding portion having rigidity that does not deform even when it receives the elastic force of a thin portion.
The power module according to claim 6, wherein
The power module which forms the 1st projection part which contacts the side part of the said sealing body in the inner wall of the said case at the side by which the said 2nd heat sink is arrange | positioned.
The sealing body is
A second conductor plate connected to the other electrode surface of the semiconductor element via solder;
A first recess having the first conductor plate exposed at the bottom is formed on one surface of the sealing body, and the other surface opposite to the one surface of the sealing body has the bottom at the bottom. A second recess exposing the second conductor plate is formed;
The power module in which the first heat sink is fitted in the first recess and the second heat sink is fitted in the first recess.
The power module according to claim 8, wherein
A first insulating sheet that faces the exposed surface of the first conductor plate and is received in the first recess;
A power module comprising: a second insulating sheet that faces the exposed surface of the second conductor plate and is housed in the second recess.
The case forms an opening for inserting the sealing body,
When projected from the direction perpendicular to the electrode surface of the semiconductor element,
The first recess is such that the length of the first side of the projection portion of the first recess close to the opening of the case is longer than the length of the second side facing the first side. Formed,
The first heat radiating plate is a power module formed such that a projection portion of the first heat radiating plate overlaps a projection portion of the first recess.
The power module according to claim 10, wherein
In the first heat radiating plate, the length of the first side of the projection side of the first heat radiating plate close to the opening of the case is longer than the length of the second side facing the first side. Power module formed as follows.
A sealing body having a semiconductor element, a conductor plate connected to the electrode surface of the semiconductor element via solder, and a sealing material for sealing the semiconductor element and the conductor plate;
A first heat radiating plate facing one surface of the sealing body, a second heat radiating plate facing the other surface opposite to the one surface of the sealing body, the first heat radiating plate, and the first A case having an intermediate member that connects two heat sinks and forms an opening for inserting the sealing body, and a method of manufacturing a power module,
When the distance between the facing surface of the first heat sink and the facing surface of the second heat sink is defined as D, and the thickness of the sealing body is defined as T,
A first step of elastically deforming a part of the intermediate member of the case such that the D is smaller than the T so that the D becomes D1 larger than the T;
A second step of inserting the sealing body from the opening of the case;
And a third step of releasing a pressing force for elastically deforming a part of the intermediate member in the first step so that the D approaches the T from the D1.
A semiconductor element, a conductor plate connected to the electrode surface of the semiconductor element via solder, the semiconductor element and the conductor plate are sealed, and a first recess is formed on one surface; A sealing body having a sealing material that forms a second recess on the other surface opposite to the surface;
A first heat radiating plate facing one surface of the sealing body and fitted in the first recess; and a second heat sink facing the other surface opposite to the one surface of the sealing body and the second recess. And a case having an intermediate member that connects the first heat radiating plate and the second heat radiating plate and forms an opening for inserting the sealing body. A method of manufacturing a module,
The distance between the facing surface of the first heat sink and the facing surface of the second heat sink is defined as D, and the distance between the bottom of the first recess and the bottom of the second recess of the sealing body is T1. And when the thickness of the sealing body is defined as T2,
The case formed so that the D is smaller than the T1, the pressing force of the sealing body inserted from the opening of the case so that the D becomes D1 larger than the T2, A first step of elastically deforming a part of the intermediate member of the case;
A second step of fitting the first heat radiating plate into the first concave portion of the sealing body and fitting the second heat radiating plate into the second concave portion of the sealing body. Production method.
JP2010100468A 2010-04-26 2010-04-26 Power module Active JP5557585B2 (en)
JP2010100468A JP5557585B2 (en) 2010-04-26 2010-04-26 Power module
PCT/JP2011/060165 WO2011136222A1 (en) 2010-04-26 2011-04-26 Power module and method for manufacturing power module
CN201180021058.9A CN102859682B (en) 2010-04-26 2011-04-26 Power model and power model manufacture method
EP11775003.4A EP2565918B1 (en) 2010-04-26 2011-04-26 Power module and method for manufacturing power module
US13/640,512 US8659130B2 (en) 2010-04-26 2011-04-26 Power module and power module manufacturing method
JP2011233606A JP2011233606A (en) 2011-11-17
JP5557585B2 true JP5557585B2 (en) 2014-07-23
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JP2010100468A Active JP5557585B2 (en) 2010-04-26 2010-04-26 Power module
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EP (1) EP2565918B1 (en)
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