JP5373150B2 - Capacitor module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a power converter capable of reducing influence of mixture noise. <P>SOLUTION: In a power converter for vehicles, a noise rejection capacitor is built in a capacitor module having a smoothing capacitor element. The noise rejection capacitor is electrically connected to an input side power supply terminal of the capacitor module at a position where distance between a connecting location of the noise rejection capacitor and the input side power supply terminal is shorter than distance between the connecting location of the noise rejection capacitor and an output side power supply terminal of the capacitor module. <P>COPYRIGHT: (C)2012,JPO&amp;INPIT

Description

  The present invention relates to a power conversion device, and more particularly to a power conversion device for driving a hybrid vehicle or an electric vehicle.

In order to reduce the size of a power conversion device, a technique for modularizing components constituting the device has been studied conventionally. For example, in the technique disclosed in Japanese Patent Application Laid-Open No. 2004-104860 (Patent Document 1), a smoothing film capacitor is mounted on a substrate, and further, a line bypass capacitor and a discharge resistor for reducing mixed noise are also provided on the substrate. Proposals to be mounted on top are made.

However, it is required to ensure the insulation of the electrical components used in the power converter and improve the reliability of the power converter.

JP 2004-104860 A

The subject of this invention is providing the capacitor | condenser module or power converter device which ensured the insulation of the electrical component and improved reliability.

According to one aspect of the capacitor module according to the present invention, a capacitor element, a filler for sealing the capacitor element, a first electrode terminal side start-up that is electrically connected to the capacitor element and rises from the filler A first electrode side capacitor terminal connected to an end of the first electrode terminal side rising portion, a second electrode terminal side rising portion electrically connected to the capacitor element and rising from the filler And a second electrode-side capacitor terminal connected to an end of the second electrode terminal side rising portion, and the first electrode terminal side rising portion and the second electrode terminal side rising portion. The second electrode side capacitor terminal is formed along a direction away from the first electrode side capacitor terminal, and is in contact with the outside of the first electrode side capacitor terminal. Surface, the second is formed lower than the connecting surface between the outer electrode side capacitor terminal, the insulating member, the first electrode side capacitor terminals are formed by bending arranged side.

Thereby, the capacitor terminal can ensure insulation.

With the capacitor module or the power conversion device using the present invention, it is possible to ensure the insulation of the electrical components and improve the reliability.

It is a figure which shows the control block of a hybrid vehicle. It is a figure explaining the electrical equipment circuit structure of an inverter apparatus. It is a perspective view which shows the external appearance of a power converter device. It is a disassembled perspective view which shows the internal structure of a power converter device. It is the figure which attached the cooling water inlet piping and the outlet piping to the aluminum casting of the housing | casing which has a cooling water flow path, (a) is a perspective view of a housing | casing, (b) is a top view of a housing | casing, (c) is It is a bottom view of a housing | casing. It is detail drawing of the bottom view of a housing | casing. It is AA sectional drawing of FIG. It is a figure which shows a power module, (a) is an upper perspective view, (b) is a top view. It is a disassembled perspective view of the DC terminal of the power module 300 regarding this embodiment. In order to make the structure of the DC bus bar easy to understand, the power module case 302 is a sectional view partially transparent. FIG. 3 is a diagram showing a current flow in a power module 300. It is a perspective view which shows the external appearance structure of the capacitor | condenser module 500 regarding this embodiment. It is a perspective view which shows the state before filling with fillers 522, such as resin, so that the inside of the capacitor | condenser module 500 shown in FIG. 12 may be understood. FIG. 14 is a diagram schematically showing a connection state of the noise filter capacitors 556 and 557 and the discharge resistor 530. 6 is a circuit diagram around a capacitor module 500. FIG. It is a figure explaining the form by which two power modules were connected with the common capacitor | condenser module like this embodiment. FIG. 5 is a diagram showing an electrical flow in an overview diagram of a capacitor module 500. It is the figure which represented the electrical flow in the general-view figure of the capacitor | condenser module 500 which concerns on other embodiment. It is the figure which represented the electrical connection inside the capacitor | condenser module 500 by physical positional relationship. It is the figure which represented the electrical connection inside the capacitor | condenser module 500 which concerns on other embodiment with the physical positional relationship. It is a schematic diagram of the A cross section of FIG. 3 is an external perspective view of a conductive member 570. FIG. FIG. 46 is an external view of a conductive member 570. It is an external appearance perspective view of the insulating cover 540 which concerns on this embodiment. It is an external appearance perspective view of the insulating paper 535 which concerns on other embodiment. It is an external appearance perspective view of the insulating cover 545 which concerns on other embodiment.

  A power converter according to an embodiment of the present invention will be described below in detail with reference to the drawings. The power conversion device according to the embodiment of the present invention can be applied to a hybrid vehicle or a pure electric vehicle. As a representative example, the power conversion device according to the embodiment of the present invention is applied to a hybrid vehicle. The control configuration and the circuit configuration of the power converter will be described with reference to FIGS. 1 and 2. FIG. 1 is a diagram showing a control block of a hybrid vehicle.

  The power conversion device according to the embodiment of the present invention is used in a vehicle-mounted power conversion device for a vehicle-mounted electrical system mounted on an automobile, in particular, a vehicle drive electrical system, and has a very severe mounting environment and operational environment. The inverter device will be described as an example. A vehicle drive inverter device is provided in a vehicle drive electrical system as a control device for controlling the drive of a vehicle drive motor, and a DC power supplied from an onboard battery or an onboard power generator constituting an onboard power source is a predetermined AC power. Then, the AC power obtained is supplied to the vehicle drive motor to control the drive of the vehicle drive motor. Further, since the vehicle drive motor also has a function as a generator, the vehicle drive inverter device also has a function of converting the AC power generated by the vehicle drive motor into DC power according to the operation mode. Yes. The converted DC power is supplied to the on-vehicle battery.

  The configuration of the present embodiment is optimal as a power conversion device for driving a vehicle such as an automobile or a truck. However, other power conversion devices such as a power conversion device such as a train, a ship, and an aircraft, and a factory facility are also included. Applicable to industrial power converters used as drive motor control devices, or household power conversion devices used in home solar power generation systems and motor control devices that drive household appliances It is.

  In FIG. 1, a hybrid electric vehicle (hereinafter referred to as “HEV”) 110 is one electric vehicle and includes two vehicle drive systems. One of them is an engine system that uses an engine 120 that is an internal combustion engine as a power source. The engine system is mainly used as a drive source for HEV. The other is an in-vehicle electric system using motor generators 192 and 194 as a power source. The in-vehicle electric system is mainly used as an HEV drive source and an HEV power generation source. The motor generators 192 and 194 are, for example, synchronous machines or induction machines, and operate as both a motor and a generator depending on the operation method.

  A front wheel axle 114 is rotatably supported at the front portion of the vehicle body. A pair of front wheels 112 are provided at both ends of the front wheel axle 114. A rear wheel axle (not shown) is rotatably supported on the rear portion of the vehicle body. A pair of rear wheels are provided at both ends of the rear wheel axle. The HEV of this embodiment employs a so-called front wheel drive system in which the main wheel driven by power is the front wheel 112 and the driven wheel to be driven is the rear wheel. You may adopt.

  A front wheel side differential gear (hereinafter referred to as “front wheel side DEF”) 116 is provided at the center of the front wheel axle 114. The front wheel axle 114 is mechanically connected to the output side of the front wheel side DEF 116. The output shaft of the transmission 118 is mechanically connected to the input side of the front wheel side DEF 116. The front wheel side DEF 116 is a differential power distribution mechanism that distributes the rotational driving force that is shifted and transmitted by the transmission 118 to the left and right front wheel axles 114. The output side of the motor generator 192 is mechanically connected to the input side of the transmission 118. The output side of the engine 120 and the output side of the motor generator 194 are mechanically connected to the input side of the motor generator 192 via the power distribution mechanism 122. Motor generators 192 and 194 and power distribution mechanism 122 are housed inside the casing of transmission 118.

  The motor generators 192 and 194 are synchronous machines having a permanent magnet on the rotor, and the AC power supplied to the armature windings of the stator is controlled by the inverter devices 140 and 142, thereby the motor generators 192 and 194. Is controlled. A battery 136 is electrically connected to the inverter devices 140 and 142, and power can be exchanged between the battery 136 and the inverter devices 140 and 142.

  In the present embodiment, the first motor generator unit composed of the motor generator 192 and the inverter device 140 and the second motor generator unit composed of the motor generator 194 and the inverter device 142 are provided. ing. That is, in the case where the vehicle is driven by the power from the engine 120, when assisting the driving torque of the vehicle, the second motor generator unit is operated as the power generation unit by the power of the engine 120 to generate power. The first electric power generation unit is operated as an electric unit by the obtained electric power. Further, in the same case, when assisting the vehicle speed of the vehicle, the first motor generator unit is operated by the power of the engine 120 as a power generation unit to generate power, and the second motor generator unit is generated by the electric power obtained by the power generation. Operate as an electric unit.

  In the present embodiment, the vehicle can be driven only by the power of the motor generator 192 by operating the first motor generator unit as an electric unit by the electric power of the battery 136. 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 machine is, for example, a motor that drives a compressor of an air conditioner or a motor that drives a hydraulic pump for control. DC power is supplied from the battery 136 to the inverter 43 device, and is converted into AC power by the inverter device 43. To the motor 195. The inverter device 43 has the same function as the inverter devices 140 and 142, and controls the phase, frequency, and power of alternating current supplied to the motor 195. For example, the motor 195 generates torque by supplying AC power having a leading phase with respect to the rotation of the rotor of the motor 195. On the other hand, by generating the delayed phase AC power, the motor 195 acts as a generator, and the motor 195 is operated in a regenerative braking state. Such a control function of the inverter device 43 is the same as the control function of the inverter devices 140 and 142. Since the capacity of the motor 195 is smaller than the capacity of the motor generators 192 and 194, the maximum conversion power of the inverter device 43 is smaller than that of the inverter devices 140 and 142, but the circuit configuration of the inverter device 43 is basically the circuit of the inverter devices 140 and 142. Same as the configuration.

  The inverter devices 140 and 142, the inverter device 43, and the capacitor module 500 are in an electrical close relationship. Furthermore, there is a common point that measures against heat generation are necessary. It is also desired to make the volume of the device as small as possible. From these points, the power conversion device described in detail below includes the inverter devices 140 and 142, the inverter device 43, and the capacitor module 500 in the casing of the power conversion device. With this configuration, a small and highly reliable device can be realized.

  Further, by incorporating the inverter devices 140 and 142, the inverter device 43, and the capacitor module 500 in one housing, it is effective in simplifying wiring and taking measures against noise. In addition, the inductance of the connection circuit between the capacitor module 500, the inverter devices 140 and 142, and the inverter device 43 can be reduced, the spike voltage can be reduced, heat generation can be reduced, and heat dissipation efficiency can be improved.

  Next, the electric circuit configuration of the inverter devices 140 and 142 or the inverter device 43 will be described with reference to FIG. In the embodiment shown in FIGS. 1 and 2, the case where the inverter devices 140 and 142 or the inverter device 43 are individually configured will be described as an example. Since the inverter devices 140 and 142 or the inverter device 43 have the same functions and the same functions, the inverter device 140 will be described here as a representative example.

  The power conversion device 200 according to the present embodiment includes an inverter device 140 and a capacitor module 500, and the inverter device 140 includes an inverter circuit 144 and a control unit 170. The inverter circuit 144 includes a plurality of upper and lower arm series circuits 150 including an IGBT 328 (insulated gate bipolar transistor) and a diode 156 that operate as an upper arm, and an IGBT 330 and a diode 166 that operate as a lower arm (FIG. 2). In this example, three upper and lower arm series circuits 150, 150, 150), an AC power line (AC bus bar) 186 from the middle point (intermediate electrode 169) of each upper and lower arm series circuit 150 to the motor generator 192 through the AC terminal 159, It is a configuration to connect. In addition, the control unit 170 includes a driver circuit 174 that drives and controls the inverter circuit 144 and a control circuit 172 that supplies a control signal to the driver circuit 174 via the signal line 176.

  The IGBTs 328 and 330 of the upper arm and the lower arm are switching power semiconductor elements, operate in response to a drive signal output from the control unit 170, and convert DC power supplied from the battery 136 into three-phase AC power. . The converted electric power is supplied to the armature winding of the motor generator 192.

  The inverter circuit 144 is configured by a three-phase bridge circuit, and a DC positive terminal 314 to which upper and lower arm series circuits 150, 150, 150 for three phases are electrically connected to the positive side and the negative side of the battery 136, respectively. And DC negative electrode terminal 316 are electrically connected in parallel.

  In the present embodiment, the use of IGBTs 328 and 330 as switching power semiconductor elements is exemplified. The IGBTs 328 and 330 include collector electrodes 153 and 163, emitter electrodes (signal emitter electrode terminals 155 and 165), and gate electrodes (gate electrode terminals 154 and 164). Diodes 156 and 166 are electrically connected between the collector electrodes 153 and 163 of the IGBTs 328 and 330 and the emitter electrode as shown. The diodes 156 and 166 have two electrodes, a cathode electrode and an anode electrode, and the cathode electrode serves as the collector electrode of the IGBTs 328 and 330 so that the direction from the emitter electrode to the collector electrode of the IGBTs 328 and 330 is the forward direction. The anode electrodes are electrically connected to the emitter electrodes of the IGBTs 328 and 330, respectively. A MOSFET (metal oxide semiconductor field effect transistor) may be used as the switching power semiconductor element. In this case, the diode 156 and the diode 166 are not necessary.

  Upper and lower arm series circuit 150 is provided for three phases corresponding to each phase winding of the armature winding of motor generator 192. The three upper and lower arm series circuits 150, 150, 150 are respectively connected to the motor generator 192 via the intermediate electrode 169 and the AC terminal 159 that connect the emitter electrode of the IGBT 328 and the collector electrode 163 of the IGBT 330, the V phase, and the W phase. Is forming. The upper and lower arm series circuits are electrically connected in parallel. The collector electrode 153 of the upper arm IGBT 328 is connected to the positive capacitor electrode of the capacitor module 500 via the positive terminal (P terminal) 157, and the emitter electrode of the lower arm IGBT 330 is connected to the capacitor module 500 via the negative terminal (N terminal) 158. Are respectively electrically connected (connected by a DC bus bar). The intermediate electrode 169 corresponding to the middle point portion of each arm (the connection portion between the emitter electrode of the IGBT 328 of the upper arm and the collector electrode of the IGBT 330 of the lower arm) is connected to the corresponding phase winding of the armature winding of the motor generator 192 with an AC connector. It is electrically connected via 188.

  Capacitor module 500 is for configuring a smoothing circuit that suppresses fluctuations in DC voltage caused by the switching operation of IGBTs 328 and 330. The positive electrode side of the battery 136 is electrically connected to the positive electrode side capacitor electrode of the capacitor module 500, and the negative electrode side of the battery 136 is electrically connected to the negative electrode side capacitor electrode of the capacitor module 500 via the DC connector 138. Thus, the capacitor module 500 is connected between the collector electrode 153 of the upper arm IGBT 328 and the positive electrode side of the battery 136, and between the emitter electrode of the lower arm IGBT 330 and the negative electrode side of the battery 136. Electrically connected in parallel to the series circuit 150.

  The control unit 170 is for operating the IGBTs 328 and 330, and generates a timing signal for controlling the switching timing of the IGBTs 328 and 330 based on input information from other control devices or sensors. And a drive circuit 174 that generates a drive signal for switching the IGBTs 328 and 330 based on the timing signal output from the control circuit 172.

  The control circuit 172 includes a microcomputer (hereinafter referred to as “microcomputer”) for calculating the switching timing of the IGBTs 328 and 330. The microcomputer receives as input information the target torque value required for the motor generator 192, the current value supplied from the upper and lower arm series circuit 150 to the armature winding of the motor generator 192, and the magnetic pole of the rotor of the motor generator 192. The position has been entered. The target torque value is based on a command signal output from a host controller (not shown). The current value is detected based on the detection signal output 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) provided in the motor generator 192. In the present embodiment, the case where the current values of three phases are detected will be described as an example, but the current values for two phases may be detected.

  The microcomputer in the control circuit 172 calculates the d and q axis current command values of the motor generator 192 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 amplifies the PWM signal, and when the driver circuit 174 drives the upper arm to the gate electrode of the corresponding IGBT 330 of the lower arm, the driver circuit 174 sets the level of the reference potential of the PWM signal. After shifting to the level of the reference potential of the upper arm, the PWM signal is amplified and output as a drive signal to the gate electrode of the corresponding IGBT 328 of the upper arm. As a result, each IGBT 328, 330 performs a switching operation based on the input drive signal.

  In addition, the control unit 170 performs abnormality detection (overcurrent, overvoltage, overtemperature, etc.) to protect the upper and lower arm series circuit 150. For this reason, sensing information is input to the control unit 170. For example, information on the current flowing through the emitter electrodes of the IGBTs 328 and 330 is input to the corresponding drive units (ICs) from the signal emitter electrode terminals 155 and 165 of each arm. Thereby, each drive part (IC) detects overcurrent, and when overcurrent is detected, the switching operation of corresponding IGBT328,330 is stopped, and corresponding IGBT328,330 is protected 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 when an over-temperature or over-voltage is detected, it stops the switching operation of all the IGBTs 328 and 330, and the upper and lower arm series circuit 150 (subtract) The semiconductor module including the circuit 150 is protected from overtemperature or overvoltage.

  The conduction and cut-off operations of the IGBTs 328 and 330 of the upper and lower arms of the inverter circuit 144 are switched in a fixed order, and the current of the stator winding of the motor generator 192 at this switching flows through a circuit formed by the diodes 156 and 166.

  As shown in the figure, the upper and lower arm series circuit 150 includes a positive terminal (P terminal, positive terminal) 157, a negative terminal (N terminal 158, negative terminal), an AC terminal 159 from the intermediate electrode 169 of the upper and lower arms, and an upper arm signal. A terminal for signal (signal emitter electrode terminal) 155, a gate electrode terminal 154 for the upper arm, a signal terminal (signal emitter electrode terminal for signal) 165 for the lower arm, and a gate terminal electrode 164 for the lower arm. The power conversion device 200 has a DC connector 138 on the input side and an AC connector 188 on the output side, and is connected to the battery 136 and the motor generator 192 through the connectors 138 and 188, respectively. Further, as a circuit for generating an output of each phase of the three-phase alternating current to be output to the motor generator, a power conversion device having a circuit configuration in which two upper and lower arm series circuits are connected in parallel to each phase may be used.

  3-7, 200 is a power converter, 10 is an upper case, 11 is a metal base plate, 12 is a housing, 13 is a cooling water inlet pipe, 14 is a cooling water outlet pipe, 420 is a cover, and 16 is a lower part. The case, 17 is an AC terminal case, 18 is an AC terminal, 19 is a cooling water flow path, and 20 is a control circuit board that holds the control circuit 172. Reference numeral 21 denotes a connector for connection to the outside, and reference numeral 22 denotes a drive circuit board that holds a driver circuit 174. Two power modules (semiconductor module units) 300 are provided, and an inverter circuit 144 is built in each power module. 700 is a flat laminated bus bar, 800 is an O-ring, 304 is a metal base, 188 is an AC connector, 314 is a DC positive terminal, 316 is a DC negative terminal, 500 is a capacitor module, 502 is a capacitor case, 504 is a positive capacitor terminal, Reference numeral 506 denotes a negative side capacitor terminal, and 514 denotes a capacitor cell.

  FIG. 3 is an external perspective view of the overall configuration of the power conversion device according to the embodiment of the present invention. The external appearance of the power conversion device 200 according to the present embodiment is as follows. The casing 12 whose top surface or bottom surface is substantially rectangular, the cooling water inlet pipe 13 provided on one of the outer circumferences on the short side of the casing 12, and the cooling water. The outlet pipe 14, the upper case 10 for closing the upper opening of the housing 12, and the lower case 16 for closing the lower opening of the housing 12 are fixedly formed. Since the shape of the bottom view or the top view of the housing 12 is substantially rectangular, it is easy to attach to the vehicle and to produce easily.

  Two sets of AC terminal cases 17 for assisting the connection with the motor generators 192 and 194 are provided on the outer periphery of the long side of the power converter 200. AC terminal 18 electrically connects power module 300 and motor generators 192 and 194, and transmits an AC current output from power module 300 to motor generators 192 and 194.

  The connector 21 is connected to a control circuit board 20 built in the housing 12 and transmits various external signals to the control circuit board 20. The DC power supply side negative electrode side connection terminal portion 510 and the DC power supply side positive electrode side connection terminal portion 512 electrically connect the battery 136 and the capacitor module 500. Here, in the present embodiment, the connector 21 is provided on one side of the outer peripheral surface on the short side of the housing 12. On the other hand, the negative electrode side connecting terminal portion 510 on the DC power source side and the positive electrode side connecting terminal portion 512 on the DC power source side are provided on the outer peripheral surface on the short side opposite to the surface on which the connector 21 is provided. That is, the connector 21 and the negative electrode side connection terminal portion 510 on the DC power supply side are arranged apart from each other. As a result, noise that enters the housing 12 from the negative electrode side connection terminal portion 510 on the DC power supply side and propagates to the connector 21 can be reduced, and the controllability of the motor by the control circuit board 20 can be improved.

  FIG. 4 is a perspective view in which the entire configuration of the power conversion device according to the embodiment of the present invention is disassembled into components.

  As shown in FIG. 4, a cooling water flow path 19 is provided in the middle of the housing 12, and two sets of openings 400 and 402 are formed in the upper part of the cooling water flow path 19 side by side in the flow direction. Two power modules 300 are fixed to the upper surface of the cooling water channel 19 so that the two sets of openings 400 and 402 are respectively closed by the power module 300. Each power module 300 is provided with fins 305 for radiating heat, and the fins 305 of each power module 300 protrude into the cooling water flow from the openings 400 and 402 of the cooling water channel 19, respectively.

  An opening 404 for facilitating aluminum casting is formed below the cooling water channel 19, and the opening 404 is closed by a cover 420. An auxiliary inverter device 43 is attached to the lower side of the cooling water passage 19. The auxiliary inverter 43 has a built-in circuit similar to the inverter circuit 144 shown in FIG. 2, and has a power module with a built-in power semiconductor element constituting the inverter circuit 144. The auxiliary inverter device 43 is fixed to the lower surface of the cooling water passage 19 so that the heat dissipation metal surface of the built-in power module faces the lower surface of the cooling water passage 19. Further, an O-ring 800 for sealing is provided between the power module 300 and the housing 12, and an O-ring 802 is also provided between the cover 420 and the housing 12. In this embodiment, the sealing material is an O-ring, but a resin material, a liquid seal, a packing, or the like may be used instead of the O-ring. In particular, when the liquid seal is used, the power converter 200 can be easily assembled. Can be improved.

  In addition, a lower case 16 is provided in the lower part of the cooling water flow path 19 so as to dissipate heat. It is fixed to the surface of the lower case 16 so as to face the surface. With this structure, cooling can be efficiently performed using the upper surface and the lower surface of the cooling water channel 19, which leads to downsizing of the entire power conversion device.

  When the cooling water from the cooling water inlet / outlet pipes 13 and 14 flows through the cooling water flow path 19, the heat radiation fins of the two power modules 300 provided side by side are cooled, and the entire two power modules 300 are cooled. Is done. The auxiliary inverter device 43 provided on the lower surface of the cooling water passage 19 is also cooled at the same time.

  Further, the casing 12 provided with the cooling water flow path 19 is cooled, whereby the lower case 16 provided at the lower portion of the casing 12 is cooled, and by this cooling, the heat of the capacitor module 500 is transferred to the lower case 16 and the casing. The capacitor module 500 is cooled by being thermally conducted to the cooling water through the body 12.

  Above the power module 300, a laminated conductor plate 700 for electrically connecting the power module 300 and the capacitor module 500 is disposed. The laminated conductor plate 700 is configured to be wide in the width direction of the two power modules 300 across the two power modules 300. Furthermore, the laminated conductor plate 700 includes a positive electrode side conductor plate 702 connected to the positive electrode side terminal of the capacitor module 500, a negative electrode side conductor plate 704 connected to the negative electrode side terminal, the positive electrode side terminal and the negative electrode side terminal. It is comprised by the insulation member arrange | positioned between. As a result, the laminated area of the laminated conductor plate 700 can be increased, so that the parasitic inductance from the power module 300 to the capacitor module 500 can be reduced. In addition, after placing one laminated conductor plate 700 on the two power modules 300, the laminated conductor plate 700, the power module 300, and the capacitor module 500 can be electrically connected. Even if it is a power converter provided, the assembly man-hour can be suppressed.

  A control circuit board 20 and a drive circuit board 22 are disposed above the laminated conductor plate 700. The driver circuit 174 shown in FIG. 2 is mounted on the drive circuit board 22, and the CPU shown in FIG. A control circuit 172 having is mounted. Further, a metal base plate 11 is disposed between the drive circuit board 22 and the control circuit board 20, and the metal base plate 11 functions as an electromagnetic shield for a circuit group mounted on both the boards 22 and 20, and also the drive circuit board. The heat generated by the control circuit board 20 and the control circuit board 20 is released and cooled. In this way, the cooling water flow path 19 is provided in the central portion of the housing 19, the power module 300 for driving the vehicle is arranged on one side thereof, and the power module 43 for auxiliary machines is arranged on the other side. Thus, cooling can be efficiently performed in a small space, and the entire power conversion device can be downsized. Further, by making the main structure of the cooling water channel 19 at the center of the casing by casting an aluminum material integrally with the casing 12, the cooling water channel 19 has the effect of increasing the mechanical strength in addition to the cooling effect. Further, by making the aluminum casting, the housing 12 and the cooling water flow path 19 are integrated with each other, heat conduction is improved, and cooling efficiency is improved.

  The drive circuit board 22 is provided with an inter-board connector 23 that passes through the metal base plate 11 and is connected to a circuit group of the control circuit board 20. The control circuit board 20 is provided with a connector 21 for electrical connection with the outside. The connector 21 transmits a signal to, for example, a lithium battery module mounted on the vehicle as the battery 136, for example, outside the power conversion device, and a signal indicating the state of the battery from the lithium battery module or a charging state of the lithium battery. A signal is sent. The inter-board connector 23 is provided in order to exchange signals with the control circuit 172 held on the control circuit board 20, and the signal line 176 shown in FIG. The signal of the switching timing of the inverter circuit is transmitted from the control circuit board 20 to the drive circuit board 22 via the signal line 176 and the board-to-board connector 23, and the drive circuit board 22 generates a gate drive signal as a drive signal. Each is applied to the gate electrode of the power module.

  Openings are formed in the upper part and the lower part of the housing 12, and these openings are closed by fixing the upper case 10 and the lower case 16 to the housing 12 with, for example, screws. A cooling water channel 19 is provided in the center of the housing 12, and the power module 300 and the cover 420 are fixed to the cooling water channel 19. In this way, the cooling water channel 19 is completed, and a water leak test of the water channel is performed. When the water leakage test is passed, the operation of attaching the substrate and the capacitor module 500 from the upper and lower openings of the housing 12 can be performed next. In this way, the cooling water flow path 19 is arranged in the center, and then the structure for performing the work of fixing the necessary parts from the upper and lower openings of the housing 12 is made, and the productivity is improved. Moreover, it becomes possible to complete the cooling water flow path 19 first and to attach other parts after the water leak test, which improves both productivity and reliability.

  FIG. 5 is a view in which a cooling water inlet pipe and an outlet pipe are attached to an aluminum casting product of the casing 12 having the cooling water flow path 19, FIG. 5A is a perspective view of the casing 12, and FIG. FIG. 5C is a top view of the housing 12, and FIG. 5C is a bottom view of the housing 12. As shown in FIG. 5, the casing 12 and a cooling water flow path 19 provided in the casing 12 are integrally cast. The upper surface or the lower surface of the housing 12 has a substantially rectangular shape, and a cooling water inlet pipe 13 for taking in cooling water is provided on the side surface of one side of the rectangular short side, and the cooling water inlet pipe 14 is provided on the same side surface. Is provided.

  The cooling water flowing into the cooling water flow path 19 from the cooling water inlet pipe 13 flows along the long side of the rectangle in the direction of the arrow 418, and the arrows 421a and 421b near the front side of the other side of the short side of the rectangle. And flows again in the direction of the arrow 422 along the long side of the rectangle, and flows out from an outlet hole (not shown). Two openings 400 and 402 are respectively formed on the outgoing side and the return side of the cooling water passage 19. The power modules 300 are fixed to the openings, respectively, and fins for heat dissipation of the power modules 300 protrude from the openings into the flow of cooling water. The power modules 300 are aligned and fixed in the flow direction of the casing 12, that is, along the long side, and by this fixing, the opening of the cooling water flow path 19 is completely blocked by, for example, the O-ring 800 or the like. The support portion 410 is formed integrally with the housing so that the The support portion 410 is located at substantially the center of the housing 12, and one power module 300 is fixed toward the inlet / outlet side of the cooling water with respect to the support portion 410, and the cooling water is connected to the support portion 410. One other power module 300 is fixed toward the folded side. A screw hole 412 shown in FIG. 5B is used to fix the power module 300 on the entrance / exit side to the cooling water flow path 19, and the opening 400 is sealed by this fixing. Further, the screw hole 414 is used to fix the power module 300 on the folding side to the cooling water channel 19, and the opening 402 is sealed by this fixing. By arranging the power module 300 so as to straddle both the outgoing side and the return side of the cooling water flow path 19 in this way, the inverter circuit 144 can be integrated on the metal base 304 at a high density. Therefore, the power conversion device 200 can be greatly reduced in size.

  The power module 300 on the inlet / outlet side is cooled by the cold cooling water from the cooling water inlet pipe 13 and the cooling water which is close to the outlet side and heated by the heat from the heat generating components. On the other hand, the folded-back power module 300 is cooled by the slightly warmed cooling water and the cooling water that is slightly cooler than the cooling water near the outlet hole 403. As a result, the arrangement relationship between the folded cooling passage and the two power modules 300 has an advantage that the cooling efficiency of the two power modules 300 is balanced.

  The support 410 is used for fixing the power module 300 and is necessary for sealing the openings 400 and 402. Further, the support portion 410 has a great effect on strengthening the strength of the housing 12. The cooling water channel 19 has a folded shape as described above, and is provided with a partition 408 that separates the going-side channel and the returning-side channel, and the partition 408 is formed integrally with the support portion 410. The partition wall 408 not only simply separates the going-side flow path and the return-side flow path but also acts to increase the mechanical strength of the housing. Also, it acts as a heat transfer passage between the turn-back passages and makes the temperature of the cooling water uniform. If the temperature difference between the inlet side and the outlet side of the cooling water is large, uneven cooling efficiency increases. Although the temperature difference to some extent is unavoidable, the partition wall 408 is formed integrally with the support portion 410, so that there is an effect of suppressing the temperature difference of the cooling water.

  FIG. 5C shows the back surface of the cooling water channel 19, and an opening 404 is formed on the back surface corresponding to the support portion 410. The opening 404 is for improving the yield of the support portion 410 and the housing 12 integrated structure formed by casting the housing. The formation of the opening 404 eliminates the double structure of the support portion 410 and the bottom portion of the cooling water channel 19 in the cast product, facilitating casting, and improving productivity.

  In addition, a through hole 406 is formed in the side portion of the cooling water passage 19. Electrical components (power module 300 and capacitor module 500) installed on both sides of the cooling water channel 19 are connected through the through hole 406.

  Moreover, since the housing | casing 12 can be manufactured as an integral structure of the cooling water flow path 19 and the housing | casing 12, it is suitable for casting production, especially aluminum die-cast production.

  FIG. 6 shows a state where the power module 300 is fixed to the upper surface opening of the cooling water passage 19 and the cover 420 is fixed to the rear surface opening. On one long side of the rectangle of the housing 12, an AC power line 186 and an AC connector 188 protrude from the housing 12.

  In FIG. 6, the through hole 406 is formed inside the other long side of the rectangle of the housing 12, and a part of the laminated conductor plate 700 connected to the power module 300 through the through hole 406 can be seen. . The auxiliary inverter device 43 is disposed in the vicinity of the side surface of the housing 12 to which the DC positive electrode side connection terminal portion 512 is connected. Further, a capacitor module 500 is disposed below the auxiliary inverter device 43 (on the side opposite to the side where the cooling water flow path 19 is present). The auxiliary machine positive terminal 44 and the auxiliary machine negative terminal 45 protrude downward (in the direction in which the capacitor module 500 is disposed), and are connected to the auxiliary machine positive terminal 532 and the auxiliary machine negative terminal 534 on the capacitor module 500 side, respectively. Is done. As a result, the wiring distance from the capacitor module 500 to the auxiliary device inverter 43 is shortened, so that the auxiliary device positive terminal 532 and the auxiliary device negative terminal 534 on the capacitor module 500 side through the metal casing 12. Noise that enters the control circuit board 20 can be reduced.

  The auxiliary inverter device 43 is disposed in the gap between the cooling water flow path 19 and the capacitor module 500, and the auxiliary inverter device 43 has the same height as the cover 420. Therefore, the auxiliary inverter device 43 can be cooled and an increase in the height of the power conversion device 200 can be suppressed.

  In FIG. 6, the cooling water inlet pipe 13 and the cooling water outlet pipe 14 are fixed by screws. In the state of FIG. 6, the water leakage inspection of the cooling water channel 19 can be performed. The auxiliary inverter device 43 is attached to the one that has passed this inspection, and the capacitor module 500 is further attached.

  FIG. 7 is a cross-sectional view of the power conversion device 200 (AA cross-section reference of FIG. 6), and the basic structure is as already described based on FIGS.

  A cooling water passage 19 (dotted line portion in FIG. 7) made of aluminum die casting is provided integrally with the housing 12 at the center in the vertical direction in the cross section of the housing 12, and is formed on the upper surface side of the cooling water passage 19. The power module 300 (the chain line portion in FIG. 7) is installed in the opened opening. The left side with respect to the paper surface of FIG. 7 is the outgoing path 19a on the cooling water direction, and the right side with respect to the paper surface is the return path 19b on the return side of the water channel. As described above, the forward path 19a and the return path 19b are each provided with an opening, and the opening is blocked by the metal base 304 for heat dissipation of the power module 300 so as to straddle both the forward path 19a and the return path 19b. Fins 305 for heat dissipation provided in 304 protrude from the opening in the flow of cooling water. In addition, an auxiliary inverter device 43 is fixed to the lower surface side of the cooling water passage 19.

  One end of the plate-like AC power line 186 bent substantially at the center is connected to the AC terminal 159 of the power module 300, and the other end protrudes from the power converter 200 to form an AC connector. The positive electrode side capacitor terminal 504 and the negative electrode side capacitor terminal 506 are electrically and mechanically connected to the positive electrode side conductor plate 702 and the negative electrode side conductor plate 704 through the through holes 406 (two-dot chain line portion in FIG. 7), respectively. The A cooling water flow path 19 that reciprocates substantially in the center of the housing 12 in the long side direction of the rectangle is disposed, and an AC connector 188, a positive-side capacitor terminal 504, and a negative-side capacitor terminal are arranged in a direction substantially perpendicular to the cooling water flow direction. 506 is arranged. Therefore, the electrical wiring is arranged in an orderly manner, which leads to a reduction in size of the power conversion device 200. Since the positive electrode side conductor plate 702 and the negative electrode side conductor plate 704 of the laminated conductor plate 700 and the AC side power line 186 project outside the power module 300 to form connection terminals, the structure is very simple, and other connection conductors are provided. Because it is not used, it is downsized. This structure improves productivity and improves reliability.

  Further, the through hole 406 is separated from the cooling water flow path 19 by a frame inside the housing 12, and the positive electrode side conductor plate 702 and the negative electrode side conductor plate 704, the positive electrode side capacitor terminal 506, and the negative electrode side capacitor terminal 504. Therefore, the reliability is improved.

  The power module 300 having a large calorific value is fixed to one surface of the cooling water channel 19 and the fins 305 of the power module 300 protrude from the opening of the cooling water channel 19 into the water channel for efficient cooling. The auxiliary inverter device 43 having a large amount of heat is cooled on the other surface of the cooling water flow path 19, and the capacitor module 500 having the next largest heat generation amount is cooled via the housing 12 and the lower case 16. Thus, since it is set as the cooling structure match | combined with much heat dissipation, while cooling efficiency and reliability improve, the power converter device 200 can be reduced more in size.

  Further, since the auxiliary inverter device 43 is fixed to the side of the capacitor module 500 of the cooling water passage 19, the capacitor module 500 can be used as a smoothing capacitor of the auxiliary inverter device 43. In this case, the wiring distance is shortened. There is. In addition, since the wiring distance is short, the inductance can be reduced.

  A drive circuit board 22 on which a driver circuit 174 is mounted is disposed above the power module 300, and a control circuit board is interposed above the drive circuit board 22 with a metal base plate 11 that enhances the effects of heat dissipation and electromagnetic shielding. 20 is arranged. The control circuit board 20 is mounted with the control circuit 172 shown in FIG. By fixing the upper case 10 to the housing 12, the power conversion device 200 according to the present embodiment is configured.

  As described above, since the drive circuit board 22 is arranged between the control circuit board 20 and the power module 300, the operation timing of the inverter circuit is transmitted from the control circuit board 20 to the drive circuit board 22, and based on that. A gate signal is generated by the drive circuit board 22 and applied to each gate of the power module 300. Since the control circuit board 20 and the drive circuit board 22 are thus arranged along the electrical connection relationship, the electrical wiring can be simplified and the power converter 200 can be downsized. The drive circuit board 22 is disposed at a distance closer to the control circuit board 20 than the power module 300 and the capacitor module 500. Therefore, the wiring distance from the drive circuit board 22 to the drive circuit board 20 is shorter than the wiring distance between other components (such as the power module 300) and the control circuit board 20. Therefore, electromagnetic noise transmitted from the DC positive electrode side connection terminal portion 512 and electromagnetic noise due to the switching operation of the IGBTs 328 and 330 can be prevented from entering the wiring from the drive circuit board 22 to the drive circuit board 20.

  The power module 300 is fixed to one surface of the cooling water channel 19 and the auxiliary inverter device 43 is fixed to the other surface, so that the power module 300 and the auxiliary inverter device 43 are simultaneously cooled by the cooling water channel 19. To do. In this case, the power module 300 has a greater cooling effect because the fins for heat dissipation are in direct contact with the cooling water in the cooling water passage 19. Further, the casing 12 is cooled by the cooling water flow path 19, and the lower case 16 and the metal base plate 11 are fixed to the casing 12, thereby cooling through the lower case 16 and the metal base plate 11. Since the metal case of the capacitor module 500 is fixed to the lower case 16, the capacitor module 500 is cooled via the lower case 16 and the housing 12. Further, the control circuit board 20 and the drive circuit board 22 are cooled via the metal base plate 11. Further, the lower case 16 is also made of a material having good thermal conductivity, receives heat generated from the capacitor module 500, conducts heat to the housing 19, and is radiated by the cooling water in the cooling water passage 19. In addition, on the other side of the cooling water passage 19 that is the lower cover 15 side, an inverter device 43 for auxiliary equipment having a relatively small capacity, which is used for an air conditioner for a vehicle, an oil pump, and a pump for other purposes, is installed. The heat generated from the auxiliary inverter device 43 is radiated by the cooling water in the cooling water passage 19 through the intermediate frame of the housing 12. In this way, the cooling water flow path 19 is provided in the center, the metal base plate 11 is provided on one side, and the lower case 16 is provided on the other side. It can cool well. Also, the components are neatly arranged inside the power conversion device 200, and the size can be reduced.

  The heat radiator that performs the heat dissipation function of the power conversion device is primarily the cooling water flow path 19, but the metal base plate 11 also performs this function (the metal base plate 11 is used to perform the heat dissipation function). Provided). The metal base plate 11 performs an electromagnetic shielding function, receives heat from the control circuit board 20 and the drive circuit board 22, conducts heat to the housing 12, and is radiated by the cooling water in the cooling water flow path 19.

  As described above, the power converter according to the present embodiment has a multilayer structure in which the radiator is a three-layered structure, that is, the metal base plate 11, the cooling water channel 19, and the lower case 16, and these The heat radiators are hierarchically installed adjacent to the respective heat generators (power module 300, control circuit board 20, drive circuit board 22, and capacitor module 500). In the center of the hierarchical structure, there is a cooling water flow path 19 that is a main radiator, and the metal base plate 11 and the lower case 16 are structured to transmit heat to the cooling water in the cooling water flow path 19 through the housing 12. . Three heat radiators (cooling water flow path 19, metal base plate 11, lower case 16) are accommodated in the housing 12 to improve heat dissipation and contribute to reduction in thickness and size.

  In addition, the capacitor element 514 according to the present embodiment is configured such that the side surface of the columnar element is crushed from both ends in order to improve the integration efficiency, and the cross section is elliptical. In the present embodiment, the cylindrical side surface forming the major axis side in the elliptical cross section is disposed to face the bottom of the capacitor case 502. Thereby, the contact area between the capacitor element 514 and the capacitor case 502 increases, the capacitor element 514 can be efficiently cooled, and the height of the power conversion device 200 can be reduced.

  When the capacitor module 500 is disposed at the lowermost part of the power conversion device 200 as in the present embodiment, the heat generated by the capacitor element 514 can be radiated to the outside via the capacitor case 502 and the lower case 16. The arrangement of the element 514 is particularly effective for improving heat dissipation.

FIG. 8A is an upper perspective view of the power module 300 according to the present embodiment, and FIG. 8B is a top view of the power module 300. FIG. 9 is an exploded perspective view of a DC terminal of the power module 300 according to the present embodiment. FIG. 10 is a cross-sectional view in which the power module case 302 is partially transparent in order to make the structure of the DC bus bar easier to understand.
FIG. 9A is a diagram in which one of the metal base 304 and three upper and lower arm series circuits, which are components of the power module 300, is extracted. FIG. 9B is an exploded perspective view of the metal base 304, the circuit wiring pattern, and the insulating substrate 334.

  302 is a power module case, 304 is a metal base, 305 is a fin (see FIG. 10), 314 is a DC positive terminal, 316 is a DC negative terminal, 318 is insulating paper (see FIG. 9), and 320U / 320L is a power module control Terminals, 328 are upper arm IGBTs, 330 are lower arm IGBTs, 156/166 are diodes, 334 is an insulating substrate (see FIG. 10), 334k is a circuit wiring pattern on the insulating substrate 334 (see FIG. 10), Reference numeral 334r denotes a circuit wiring pattern 337 (see FIG. 10) under the insulating substrate 334.

  The power module 300 is roughly divided into, for example, a semiconductor module portion including wiring in a power module case 302 made of a resin material, a metal base 304 made of a metal material such as Cu, Al, AlSiC, and a connection terminal ( DC positive terminal 314, control terminal 320U, etc.). As terminals to be connected to the outside, the power module 300 has U, V, and W phase AC terminals 159 for connecting to the motor, and a DC positive terminal 314 and a DC negative terminal 316 that are connected to the capacitor module 500. ing.

  The semiconductor module part is provided with upper and lower arms IGBTs 328 and 330, diodes 156/166 and the like on an insulating substrate 334, and is protected by a resin or silicon gel (not shown). The insulating substrate 334 may be a ceramic substrate or a thinner insulating sheet.

  FIG. 8B shows an arrangement configuration in which the upper and lower arm series circuits are specifically arranged on the insulating substrate 334 made of ceramic having good thermal conductivity fixed to the metal base 304. It is explanatory drawing which shows a figure and its function. The IGBTs 328 and 330 and the diodes 327 and 332 shown in FIG. 8B respectively connect two chips in parallel to form an upper arm and a lower arm, and increase the current capacity that can be supplied to the upper and lower arms.

  As shown in FIG. 9, the DC terminal 313 built in the power module 300 has a laminated structure of a DC negative terminal 316 and a DC positive terminal 314 with an insulating paper 318 interposed therebetween (dotted line portion in FIG. 9). Further, the ends of the DC negative electrode terminal 316 and the DC positive electrode terminal 314 are bent in opposite directions to form a negative electrode connecting portion 316a and a positive electrode connecting portion 314a for electrically connecting the laminated conductor plate 700 and the power module 300. To do. By providing two connection portions 314a (or 316a) with the laminated conductor plate 700, the average distances from the negative electrode connection portion 316a and the positive electrode connection portion 314a to the three upper and lower arm series circuits are substantially equal. Variations in parasitic inductance in 300 can be reduced.

  Further, when the DC positive terminal 314, the insulating paper 318, and the DC negative terminal 316 are laminated and assembled, the negative electrode connecting portion 316a and the positive electrode connecting portion 314a are bent in opposite directions. The insulating paper 318 is bent along the negative electrode connecting portion 316a to ensure an insulating creepage distance between the positive and negative terminals. As the insulating paper 318, when heat resistance is required, a sheet in which polyimide, meta-aramid fiber, polyester with improved tracking properties, or the like is used is used. In addition, in consideration of defects such as pin fall, two sheets are stacked to increase reliability. Also, in order to prevent tearing or tearing, the corners are rounded or the sag surface at the time of punching faces the insulating paper so that the edge of the terminal does not touch the insulating paper. In this embodiment, insulating paper is used as the insulator, but as another example, the terminal may be coated with the insulator. In order to reduce the parasitic inductance, for example, in the case of a 600V withstand voltage power module, the distance between the positive electrode and the negative electrode is 0.5 mm or less, and the thickness of the insulating paper is half or less.

  Further, the DC positive terminal 314 and the DC negative terminal 316 have connection ends 314K and 316K for connecting to the circuit wiring pattern 334K. There are two connection ends 314K, 316K for each phase (U, V, W phase). Thereby, as will be described later, it is possible to connect to a circuit wiring pattern in which two small loop current paths are formed for each arm of each phase. Each connection end 314K, 316K protrudes in the direction of the circuit wiring pattern 334K, and its tip is bent to form a joint surface with the circuit wiring pattern 334K. The connection ends 314K, 316K and the circuit wiring pattern 334K are connected via solder or the like, or directly connected to each other by ultrasonic welding.

  The power module 300, particularly the metal base 304, expands and contracts due to a temperature cycle. Due to the expansion and contraction, the connection portion between the connection ends 314K and 316K and the circuit wiring pattern 334K may be cracked or broken. Therefore, in the power module 300 according to the present embodiment, as shown in FIG. 9, the laminated flat surface portion 319 formed by laminating the DC positive terminal 314 and the DC negative terminal 316 is provided on the side where the insulating substrate 334 is mounted. Thus, the laminated flat surface portion 319 can be warped in response to the warping of the metal base 304 caused by the expansion and contraction described above. It becomes. Therefore, the rigidity of the connection ends 314 </ b> K and 316 </ b> K formed integrally with the laminated flat surface portion 319 can be reduced with respect to the warp of the metal base 304. Therefore, the stress applied in the vertical direction of the joint surface between the connection ends 314K and 316K and the circuit wiring pattern 334K can be relaxed, and cracks or breakage of the joint surface can be prevented.

  In addition, the lamination plane part 319 according to the present embodiment has the width direction length of the lamination plane part 319 so that the metal base 304 can bend in response to both the width direction and the depth direction curvature. The length in the depth direction is increased to 130 mm and the length in the depth direction to 10 mm. In addition, the thickness of each of the stacked flat surface portions 319 of the DC positive electrode terminal 314 and the DC negative electrode terminal 316 is set to be relatively thin as 1 mm so as to facilitate the warping operation.

  As shown in FIG. 10, the metal base 304 has a fin shape 305 on the opposite side of the insulating substrate 334 in order to efficiently radiate heat to the cooling water by being immersed in the cooling water flow path. In addition, the metal base 304 is mounted with an IGBT or a diode constituting an inverter circuit on one surface, and a resin power module case 302 is provided on the outer periphery of the metal base 304. The fin 305 is brazed to the other surface of the metal base 304 or the metal base 304 and the fin 305 are integrally formed by forging. The metal base 304 and the fin 305 are integrally formed by forging, so that the productivity of the power module 300 is improved, the thermal conductivity from the metal base 304 to the fin 305 is improved, and the heat dissipation of the IGBT and the diode is improved. Can be made. Further, by setting the Vickers hardness of the metal base 304 to 60 or more, the ratchet deformation of the metal base 304 caused by the temperature cycle can be suppressed, and the sealing performance between the metal base 304 and the housing 12 can be improved. Further, as shown in FIG. 10A, fins 305 are provided corresponding to the upper and lower arms, respectively, and these fins 305 project into the water channel from the opening of the reciprocating cooling water channel 19. A metal surface around the fin 305 of the metal base 304 is used to close an opening provided in the cooling water channel 19.

  In addition, although the fin 305 shape of this embodiment is a pin type, as another embodiment, the straight type formed along the flow direction of cooling water may be sufficient. When the straight type is used for the fin 305 shape, the pressure for flowing the cooling water can be reduced, and when the pin type is used, the cooling efficiency can be improved.

  An insulating substrate 334 is fixed to one surface of the metal base 304, and an upper arm IGBT 328, an upper arm diode 156, a lower arm IGBT 330, and a lower arm are fixed to the insulating substrate 334 with solder 337. The chip of the diode 166 is fixed.

  As shown in FIG. 11A, the upper and lower arm series circuit 150 includes an upper arm circuit 151 and a lower arm circuit 152, a terminal 370 for connecting the upper and lower arm circuits 151 and 152, and an AC power for output. An AC terminal 159 is provided. As shown in FIG. 11B, the upper arm circuit 151 includes an insulating substrate 334 on which a circuit wiring pattern is formed on a metal base 304, and further an IGBT 328 and a diode 156 on the circuit wiring pattern 334k. Prepare.

  In the IGBT 328 and the diode 156, the electrode on the back surface side and the circuit wiring pattern 334k are joined by solder. The insulating substrate 334 on which the circuit wiring pattern is formed has a so-called solid pattern having no pattern on the surface (back surface) opposite to the circuit wiring pattern surface. The solid pattern on the back surface of the insulating substrate and the metal base 304 are joined by solder. Similarly to the upper arm, the lower arm circuit 152 is mounted on the insulating substrate 334 disposed on the metal base 304, the circuit wiring pattern 334k wired on the insulating substrate 334, and the circuit wiring pattern 334k. The IGBT 330 and the diode 166 are provided.

  The electrodes on the back side of the IGBT 330 and the diode 166 are also joined to the circuit wiring pattern 334k by solder. In addition, each arm of each phase in the present embodiment is configured by connecting two sets of the circuit units in parallel with one set of the circuit unit in which the IGBT 328 and the diode 156 are connected in parallel. How many sets of these circuits are connected in parallel is determined by the amount of current supplied to the motor 192. If a larger current than the current supplied to the motor 192 according to the present embodiment is required, the circuit portion is Three or more sets are connected in parallel. On the other hand, when the motor can be driven with a small current, each arm of each phase is configured by only one set of circuit units.

A current path of the power module 300 will be described with reference to FIG. A path of current flowing in the upper arm circuit of the power module 300 is shown below.
(1) One side electrode (element side) of the IGBT 328 for the upper arm and the diode 156 for the upper arm via the connection conductor part 371U from the DC positive electrode terminal 314 (not shown) and (2) the connection conductor part 371U through the element side connection conductor part 372U. (3) Connection conductor portion 373U from the other electrode of upper arm IGBT 328 and upper arm diode 156 via wire 336, (4) Connection from connection conductor portion 373U The connection conductor portion 371D flows through the connection portions 374U and 374D of the terminal 370. As described above, the upper arm is configured by connecting two sets of circuit units in which IGBT 328 and diode 156 are connected in parallel, in parallel. Therefore, in the current path of (2), the current is branched into two at the element side connection conductor portion 372U, and the branched current flows to the two sets of circuit portions.

A current path flowing through the lower arm circuit of the power module 300 is shown below.
(1) One side electrode of the lower arm IGBT 330 and the upper arm diode 166 from the connection conductor part 371D via the element side connection conductor part 372D (the electrode on the side connected to the element side connection conductor part 372D), (2) From the other side electrode of the lower arm IGBT 330 and the lower arm diode 166, the connection conductor portion 373D flows through the wire 336, and (3) the DC negative electrode terminal 316 (not shown) flows from the connection conductor portion 373D. In addition, since the lower arm is configured by connecting two sets of circuit units in which the IGBT 330 and the diode 166 are connected in parallel in the same manner as the upper arm, in the current path of (1) above, the current is supplied to the element side connecting conductor unit. It is branched into two at 371D, and the branched current flows to two sets of circuit units.

  Here, the connection conductor portion 371U for connecting the IGBT 328 (and the diode 156) of the upper arm circuit and the DC positive electrode terminal 314 (not shown) is disposed near the substantially central portion of one side of the insulating substrate 334. The IGBT 328 (and the diode 156) is mounted in the vicinity of the other side that is opposite to the one side of the insulating substrate 334 on which the connection conductor portion 371U is disposed. In the present embodiment, the two connecting conductor portions 373U are arranged in a row on the one side of the insulating substrate 334 with the connecting conductor portion 371U interposed therebetween.

  Such a circuit pattern and a mounting pattern, that is, a circuit wiring pattern on the insulating substrate 334, includes two wiring patterns (371U) on both sides of a generally T-shaped wiring pattern and a generally T-shaped vertical bar (371U). By mounting the terminals from the connection ends 371U and 373U, the transient current path at the time of switching of the IGBT 328 is an M-shaped current path as indicated by an arrow 350 (broken line) in FIG. It becomes two small loop current paths (the direction of the arrow is when the lower arm is turned on). A magnetic field 350H in the direction of the arrow 350H (solid line) in FIG. 11B is generated around these two small loop current paths. The magnetic field 350H induces an induced current, so-called eddy current 340, in the metal base 304 disposed below the insulating substrate 334. The eddy current 340 generates a magnetic field 340H in a direction that cancels the magnetic field 350H, and can reduce the parasitic inductance generated in the upper arm circuit.

  Further, the two small loop currents described above can generate two U-turn currents such that currents flowing on the insulating substrate 334 cancel each other. For this reason, as shown in the magnetic field 350H of FIG. 9B, a smaller loop magnetic field is generated inside the power module 300, and therefore, the parasitic inductance can be reduced. Furthermore, since the magnetic field loop generated at the time of switching is small and the magnetic field loop can be confined inside the power module, the induced current to the housing outside the power module is reduced, and the malfunction of the control board or the outside of the power converter Electromagnetic noise can be prevented.

The lower arm circuit side also has the same circuit wiring pattern and mounting pattern as the above upper arm.
That is, the connection conductor portion 371D for connecting the IGBT 330 (and the diode 166) of the lower arm circuit and the DC negative electrode terminal 316 (not shown) is disposed in the vicinity of the substantially central portion of one side of the insulating substrate 334. The IGBT 330 (and the diode 166) is mounted in the vicinity of the other side opposite to the one side of the insulating substrate 334 on which the connection conductor portion 371D is disposed. In the present embodiment, the two connecting conductor portions 373D are arranged in a row on the one side of the insulating substrate 334 with the connecting conductor portion 371D interposed therebetween.

  By using such a circuit wiring pattern and a mounting pattern, the above-described parasitic inductance is also reduced on the lower arm circuit side. In the present embodiment, the entrance of the current path of each arm of each phase is, for example, the connection conductor part 371U sandwiched between the two connection conductor parts 373U, while the exit of the current path is the two connection conductor parts 373U. It has become. However, even if these inlets and outlets are reversed, the aforementioned small loop current path is formed in each arm of each phase. Therefore, as described above, it is possible to reduce the parasitic inductance of each arm of each phase and prevent electromagnetic noise.

  The detailed structure of the capacitor module 500 of the present embodiment will be described below with reference to FIGS. FIG. 12 is a perspective view showing an external configuration of the capacitor module 500 according to the present embodiment. FIG. 13 is a perspective view showing a state before filling with a filler 522 such as resin so that the inside of the capacitor module 500 shown in FIG. 12 can be seen.

  12 and 13, 500 is a capacitor module, 502 is a capacitor case, 504 is a negative side capacitor terminal, 506 is a positive side capacitor terminal, 510 is a DC negative side connection terminal part, 512 is a DC positive side connection terminal part, 514 Represents a capacitor element.

  As shown in FIG. 12, the capacitor module 500 according to the present embodiment is disposed in the lower part of the housing 12 and mounted on the upper part of the lower case 16. The capacitor case 502 is fixed to the lower case 16 at four corners by bolts 559A to 559D. The capacitor case 502 and the lower case 16 are in contact with each other via a heat dissipating grease (not shown). Thereby, the heat generated by the capacitor element 514 can be released to the metal lower case 16 via the capacitor case 502 and the heat dissipating grease. Further, the vibration of the vehicle can be prevented from being transmitted to the capacitor case 502 by the adhesive force of the heat dissipating grease.

  The bolt hole 549 is a hole through which a bolt for fixing the lower case 16 to the housing 12 passes. Bolt holes 548 </ b> A to 548 </ b> C are holes through which bolts for fixing power conversion device 200 to the vehicle body side pass.

  One positive terminal rising portion 526 and one negative terminal rising portion 524 form a set, and four sets of laminated bus bars are formed along the longitudinal side of the capacitor module 500. The leading ends of these rises are bent in the opening direction to form positive side capacitor terminals 506A to 506D and negative side capacitor terminals 504A to 504D. The insulating covers 540A to 540D are interposed in each of the four sets of laminated bus bars to ensure a creepage distance between the terminals and the positive and negative electrodes of the rising portion.

  As shown in FIG. 13 (a), a plurality of laminated conductor plates composed of a negative electrode conductor plate 505 and a positive electrode conductor plate 507, four in this embodiment, a direct current (battery) negative electrode side connection terminal portion 510 and a direct current ( Battery) It is electrically connected in parallel to the positive electrode side connection terminal portion 512. The negative electrode conductor plate 505 and the positive electrode conductor plate 507 are provided with a plurality of terminals 516 and terminals 518 for connecting the positive and negative electrodes of a plurality of capacitor elements 514 in parallel.

  A capacitor element 514, which is a unit structure of the power storage unit of the capacitor module 500 shown in FIG. 13B, is formed by laminating and winding two films each having a metal such as aluminum deposited thereon and winding them. Each is constituted by a film capacitor 515 having a positive electrode and a negative electrode. The positive and negative electrodes are manufactured by spraying a conductor such as tin, with the wound shaft surfaces being the positive and negative electrodes 508, respectively.

  Further, the negative electrode conductor plate 505 and the positive electrode conductor plate 507 are formed of thin plate-like wide conductors, have a laminated structure via insulating paper (not shown), and reduce parasitic inductance. Terminals 516 and 518 for connecting to the electrode 508 of the capacitor element 514 are provided at the end of the laminated conductor. Terminals 516 and 518 are electrically connected to electrodes 508 of two capacitor elements 514 by soldering or welding. Capacitor cell layout and conductor structure with the connection surface on the outside so that it can be easily inspected and inspected by a soldering device or a welding machine. Configure. By creating such a cell group, it can be increased or decreased according to the capacitor capacity, which is suitable for mass production. A plurality of terminals 516 and 518 may be provided in order to reduce parasitic inductance and to dissipate heat.

  Further, the negative electrode conductor plate 505 and the positive electrode conductor plate 507 constitute the negative electrode side capacitor terminal 504 and the positive electrode side capacitor terminal 506 for bending the end portions of the thin plate-like wide conductors and connecting to the DC side conductor plate 700. (See FIG. 12). Moreover, the negative electrode conductor plate 505 and the positive electrode conductor plate 507 are connected to wiring bus bars 585 and 586 in the capacitor module by bending the end portions of the thin plate-like wide conductors. At the ends of the wiring bus bars 585 and 586, a direct current negative electrode side connection terminal portion 510 and a direct current positive electrode side connection terminal portion 512 that are connected to terminals that receive battery power are formed.

  As shown in FIG. 13, the capacitor module 500 is configured by a total of eight capacitor cells 514 in which two element groups are arranged vertically in four rows. There are four pairs of positive and negative capacitor terminals 504 and 506 connected to the DC side conductive plate 700 and DC negative side connection terminal portions 510 and 512 for receiving battery power. The positive and negative capacitor terminals 504 and 506 are formed with openings 509 and 511 in which nuts are embedded so that the positive and negative DC terminals 316 and 314 of the power module 300 can be screwed together.

  The capacitor module 500 generates heat due to a ripple current at the time of switching due to the electric resistance of the metal thin film and the internal conductor (terminal) deposited on the film inside the capacitor element. For the moisture resistance of the capacitor element, the capacitor cell and the inner conductor (terminal) are molded into the capacitor case 502 with resin (see FIG. 12). For this reason, the capacitor element and the internal conductor are in close contact with the capacitor case 502 via the resin, and the heat generated by the capacitor cell is easily transmitted to the case. Further, in this structure, since the negative electrode conductor plate 505, the positive electrode conductor plate 507, the capacitor element electrode 508, and the terminals 516 and 518 are directly connected, the heat generated in the capacitor cell is directly transmitted to the negative electrode and the positive electrode conductor, and is transferred to the mold resin by the wide conductor. It has a structure where heat can be easily transmitted. For this reason, heat is transferred well from the capacitor case 502 to the lower case 16, and from the lower case 16 to the housing 12 and further to the cooling water passage 19, and heat dissipation can be secured.

  In the present embodiment, as shown in FIG. 13, the negative electrode conductor plate 505 and the positive electrode conductor plate 507 are configured to be independently arranged vertically in four rows, but the four rows of negative electrode conductors 505 and positive electrode conductors 507 are arranged. As an integrated wide conductor plate, all the capacitor cells 514 may be connected to the wide conductor plate. As a result, the number of components can be reduced, productivity can be improved, and the capacitances of all capacitor cells 514 can be used substantially evenly, thereby extending the component life of the entire capacitor module 500. be able to. Furthermore, parasitic inductance can be reduced by using a wide conductor plate.

  FIG. 14 is a diagram schematically showing a connection state of the noise filter capacitors 556 and 557 and the discharge resistor 530.

  The main components of the main circuit of the power conversion device 200 include a power module 300, a capacitor module 500 for smoothing, capacitors 556 and 557 (noise removing capacitor module), and a discharge resistor 530. These components often fall into the category of large size among the components in the power conversion device 200, and often become an obstacle to downsizing the power conversion device. Moreover, even if the size can be reduced, there is a risk that contradictory matters such as a decrease in cooling performance, an increase in wiring inductance, and mixed noise may appear. A configuration for reducing the size of the entire power conversion device while suppressing an increase in cooling performance, wiring inductance, or mixed noise will be described below.

  14 and 15 illustrate how the capacitor module 500 is electrically connected to the power module 300 and the battery 136. FIG. FIG. 16 is a diagram illustrating a configuration in which two power modules are connected to a common capacitor module as in the present embodiment. As described above, the capacitor module 500 includes the discharge resistor 530 and the capacitors 556 and 557 in addition to the capacitor element 514 for smoothing. The role of the capacitor element 514 is to smooth the ripple voltage and ripple current riding on the DC circuit portion and to supply stable power to the power module 300. On the other hand, the capacitors 557 and 556 have a noise removal function.

  Each component is placed at a position where these functions are utilized to the fullest, and they are integrated, that is, modularized to achieve miniaturization. The capacitor element 514, the discharge resistor 530, and the capacitors 556 and 557 correspond to the portion surrounded by the broken line in FIG.

  Capacitors 557 and 556 are arranged adjacent to the DC-side positive and negative-side input terminal portions 512 and 510 (first DC power supply terminals) connected to battery 136. Capacitors 557 and 556 include terminals (second DC power supply terminals) for connection to DC side input terminal portions 512 and 510 (first DC power supply terminals). And the distance between the said terminal (2nd DC power supply terminal) and the DC side input terminal part 512,510 (1st DC power supply terminal) is the said terminal (2nd DC power supply terminal) and the positive / negative side capacitor terminals 504,506. Capacitors 557 and 556 are arranged so as to be shorter than the distance between them. On the other hand, one terminal of these capacitors 556 and 557 is grounded to the ground terminal 558. As shown in FIG. 12, the ground terminal 558 is fastened together when the bolt 559B is fixed to the housing 12. That is, the capacitors 556 and 557 are grounded and the capacitor module 500 is fixed to the housing 12 in common.

  The effect by the above configuration will be described with reference to FIG. FIG. 17 is a diagram showing an electrical flow in the overview diagram of the capacitor module 500. The current from the battery 136 enters the capacitor module 500 from the DC side input terminal portions 512 and 510, passes through the smoothing capacitor element group 515, and is sent to the power module 300 via the positive and negative capacitor terminals 506 and 504. That is, the smoothed power is supplied to the power module.

  On the other hand, the capacitors 557 and 556 and the terminals (second DC power supply terminals) of the capacitors 557 and 556 are arranged in the immediate vicinity of the DC input terminal portions 512 and 510, thereby efficiently removing noise from the power supply. be able to. In particular, with the above configuration, it is possible to prevent the capacitors 557 and 556 from functioning as a part of the ripple smoothing capacitor under the influence of the switching of the power module 300 and failing to perform the noise removal function. it can. Further, heat generation of the capacitors 557 and 556 themselves due to the capacitors 557 and 556 functioning as a part of the ripple smoothing capacitor can be suppressed. Note that the wirings 552 and 554 extending from the capacitors 557 and 556 have a laminated structure using an insulating layer using a plate-like conductor, so that the wiring has a low inductance.

  FIG. 18 is a diagram showing another embodiment relating to the positional relationship among the capacitors 557 and 556, the DC side input terminal portions 512 and 510, and the positive and negative side capacitor terminals 504 and 506.

  The embodiment of FIG. 18 differs from the embodiment of FIG. 17 in that the DC side input terminal portions 512 and 510 are arranged on the opposite side of the positive and negative side capacitor terminals 504 and 506 with the capacitor element group 515 interposed therebetween. Is a point. Further, the capacitors 557 and 556 and the terminals (second DC power supply terminals) of the capacitors 557 and 556 are arranged in the immediate vicinity of the DC side input terminal portions 512 and 510 as in the embodiment of FIG. Specifically, the capacitors 557 and 556 include terminals (second DC power supply terminals) for connecting to the DC side input terminal portions 512 and 510 (first DC power supply terminals), and the terminals (second DC power supply terminals). ) And the DC side input terminal portions 512 and 510 (first DC power supply terminal) are shorter than the distance between the terminal (second DC power supply terminal) and the positive and negative side capacitor terminals 504 and 506. 557 and 556 are arranged.

  With such a configuration, the capacitors 557 and 556 are less susceptible to the influence of switching of the power module 300, and much of the capacitance of the capacitors 557 and 556 can be used for noise removal and mixed into the power conversion device. The effect of noise can be reduced.

  Hereinafter, the arrangement of the discharge resistors 530 according to the present embodiment will be described.

  As shown in FIGS. 12 and 14, a discharge resistor 530 is disposed on the side of the outer wall of the capacitor case 502. In the present embodiment, the discharge resistor 530 is disposed on the side of the capacitor module 500, but may be another location as long as it does not thermally affect the inside of the capacitor module. For example, the discharge resistor 530 may be mounted above the exposed surface of the filler 522 in a state of floating about several millimeters. With this arrangement, the mounting area of the capacitor element 514 is not reduced, and the power converter can be downsized in the width direction.

  The positional relationship between the discharge resistor 530 and the capacitor module 500 in the present embodiment is as shown in FIG. The discharge resistor 530 is fixed to the lower case 16. At this time, a bracket or the like may be used as a fixing method, or an adhesive or the like may be applied between the discharge resistor 530 and the lower case 16. In other words, it is only necessary to form a heat transfer path for the discharge resistor 530 between the discharge resistor 530 and the lower case 16.

  Further, when the discharge resistor 530 is disposed on the side of the capacitor module 500, a part of the capacitor case 502 and a part of the filler 522 exist in the space between the discharge resistor 530 and the capacitor element 514. That is, since the heat generated by the discharge resistor 530 is difficult to be transmitted to the capacitor element 514, the heat from the discharge resistor 530 can be dissipated downward and insulated from the capacitor element 514.

  The discharge resistor 500 is provided with one lead 531 and one lead 532 respectively for the positive electrode and the negative electrode, and these are electrically connected to the capacitor element 514.

  In the present embodiment, as shown in FIG. 14, the discharge resistor 530 is disposed on the opposite side of the capacitor case 502 from the side on which the DC side input terminal portions 512 and 510 are formed. With such an arrangement, the discharge resistor 530, which is a heat generation source, is separated from the capacitor element 514 and the DC-side input terminal portions 512 and 510. Therefore, when viewed from the power converter 200 as a whole, heat is concentrated to one pole. Since there is nothing to do, the heat balance can be averaged.

  FIG. 19 is a diagram showing the electrical connection inside the capacitor module 500 in a physical positional relationship. From this figure, the distance between the terminals of the capacitors 557 and 556 (second DC power supply terminal) and the DC side input terminal portions 512 and 510 (first DC power supply terminal) is the same as the terminal (second DC power supply terminal) and the positive and negative electrodes. Since the distance is shorter than the distance between the side capacitor terminals 504 and 506, it can be seen that the power module 300 is less affected by the switching.

  Further, capacitors 557 and 556 for removing noise from the DC-side input terminal portions 512 and 510 that receive power from the battery 136, and a discharge resistor 530 for discharging the charge of the capacitor element 514 constitute one module. Yes. By modularizing components that are functionally closely related in this way, the wiring distance of each component can be reduced, and the inductance can be reduced and the size can be reduced.

  FIG. 20 is a diagram showing an electrical connection relationship in a case where the negative conductor 505 and the positive conductor 507 are formed as an integrated wide conductor plate and all capacitor cells 514 are connected to the wide conductor plate. Even in such a configuration, the components are modularized as shown in FIG. 19, and the same effects as in FIG. 19 are exhibited.

  FIG. 21 is a schematic diagram of a cross section A in FIG. 3. An auxiliary inverter device 43 is fixed immediately below the cooling water passage 19. The capacitor module 500 provides the same smoothing function not only to the motor driving power module 300 but also to the auxiliary inverter device 43 electrically connected to the capacitor module 500 in parallel.

  In the present embodiment, DC-side input terminal portions 512 and 510 are provided in the capacitor module 500, and an auxiliary inverter device 43 is disposed in the vicinity of the capacitor module 500. In this embodiment, a conductive member 570 shown in FIG. 22 is used as a member responsible for these electrical connections.

  As shown in FIG. 22, the conductive member 570 includes a negative electrode side conductive member 571, a positive electrode side conductive member 572, insulating paper 581, a negative electrode side resin bracket 582, a positive electrode side resin bracket 583, Consists of. The negative electrode side conductive member 571 and the positive electrode side conductive member 572 have a + (plus) shape when viewed from the (A) direction of FIG. The members formed in the vertical direction of the negative electrode side conductive member 571 and the positive electrode side conductive member 572 are bent in an L shape in the same direction.

  Since the negative electrode side conductive member 571 and the positive electrode side conductive member 572 are formed in a laminated state with the insulating paper 581 interposed therebetween, wiring inductance is reduced. Further, since the positive electrode side resin bracket 583 is formed so as to cover a portion excluding the terminal portion formed at the tip thereof, electrical contact between the positive electrode side conductive member 572 and the metal casing 12 is prevented. can do.

  As shown in FIG. 23B, the bent members of the negative electrode side conductive member 571 are a negative electrode DC input terminal 573 and a negative DC output terminal 574. On the other hand, the members of the positive electrode side conductive member 572 bent into an L shape are the positive electrode side DC input terminal 577 and the positive electrode side DC output terminal 578.

  Power is supplied from the battery 136 to the positive side DC input terminal 577 and the negative side DC input terminal 573. Part of this power is supplied into the power conversion device 200. On the other hand, the remaining power is output from the positive side DC output terminal 578 and the negative side DC output terminal 574 without being supplied into the power converter 200. The output electric power is supplied to other inverters such as an inverter for an air conditioner in a vehicle cabin via an electric wire (not shown). That is, the conductive member 570 functions as a relay point for supplying power from the battery 136 to the air conditioner inverter in addition to the function as a terminal for supplying power to the power conversion device 200. With such a configuration, the electric wire from the battery 136 to the air conditioner inverter can be shortened (distance from the power conversion device 200 to the air conditioner inverter), and the wiring work of the electric wires in the vehicle interior becomes easy.

  Of the members formed in the lateral direction of the negative electrode side conductive member 571 and the positive electrode side conductive member 572, the left side member extends downward and forms a terminal for connecting to the auxiliary inverter device 43. To do.

  Of the members formed in the lateral direction of the negative electrode side conductive member 571 and the positive electrode side conductive member 572, the right side member has its tip extending downward, and the member extending downward is the negative electrode DC input / output The terminals 573 and 574 and the positive side DC input / output terminals 577 and 578 are bent to the opposite side to the bending direction. Further, the tip of the bent member is bent vertically and downward, and the end thereof is connected to the DC side input terminal portions 512 and 510.

  In the case of the power conversion device shown in FIG. 21A, the DC side input terminal portions 512 and 510 of the capacitor module 500 protrude vertically upward, and the terminal of the auxiliary inverter device 43 protrudes vertically downward. Yes. If it is going to connect the electroconductive member 570 which concerns on this embodiment to such a terminal, the height of a power converter device will increase by the height of a terminal.

  Therefore, in the power conversion device according to the present embodiment, as shown in FIG. 21B, the DC side input terminal portions 512 and 510 of the capacitor module 500 are bent at two locations, and the DC side input terminal portions 512 and 510 are bent. The tip of the capacitor module case 502 is formed on the side of the capacitor module case 502. Further, the terminal of the inverter device for auxiliary equipment 43 is also bent at two places, and the tip of the terminal is formed so as to be located on the side of the inverter device for auxiliary equipment 43.

  The DC side input terminal portions 512 and 510 and the terminals of the auxiliary inverter device 43 are connected to the conductive member 570, whereby the auxiliary device inverter 43 and the capacitor module 500 are connected to the side of the battery 136. Connection terminals can be arranged. Thereby, the increase in the height direction of a power converter device can be suppressed.

  The DC-side input terminal portions 512 and 510 may be formed so as to protrude directly from the side wall of the capacitor module case 502. Similarly, the terminal of the auxiliary inverter device 43 is connected to the side wall of the auxiliary inverter device 43. Alternatively, it may be formed directly.

  FIG. 24 is an external perspective view of the insulating cover 540 according to the first embodiment. The insulating cover 540 is substantially rectangular. The upper rising portion 541 and the side rising portions 542 and 543 are provided on the outer edge of the insulating cover main surface 544 and in the vertical direction of the insulating cover main surface 544. There is no rising portion on the outer edge below the main surface 544 of the insulating cover. The insulating cover 540 is inserted between the negative terminal rising part 524 and the positive terminal rising part 526 from a place where the rising part does not exist.

  The inserted insulating cover 540 is hooked to the positive capacitor terminal 506 by the upper rising portion 541 and is fixed between the negative terminal rising portion 524 and the positive terminal rising portion 526. The upper rising portion 541 is directed to the positive electrode side capacitor terminal 506 side. Thereby, the exposed part of the positive electrode side capacitor terminal 506 can be covered, and insulation of the terminal can be ensured.

  In the capacitor module 500 according to the present embodiment, in order to reduce the wiring inductance from the capacitor module 500 to the power module 300, the negative terminal rising part 524 and the positive terminal rising part 526 are formed in a stacked state. However, it is necessary to ensure insulation between the negative terminal rising part 524 and the positive terminal rising part 526. Therefore, the upper rising part 541, the side rising parts 542, 543 of the insulating cover 540 according to the first embodiment ensure a creepage distance between the negative terminal rising part 524 and the positive terminal rising part 526. Insulation has been achieved.

  Like the insulating cover 540 according to the present embodiment, by forming the upper rising portion 541 and the like simultaneously with the molding of the insulating cover 540, work such as bending the insulating paper becomes unnecessary, and workability is improved. Even when the distance between the inner wall of the housing 12 and the negative electrode terminal rising portion 524 is short, the side rising portion 543 of the insulating cover 540 according to the present embodiment interferes with the inner wall of the housing 12. There is nothing.

  FIG. 25 is an external perspective view of the insulating paper 535 according to the second embodiment. The insulating paper 535 according to the present embodiment differs from the insulating cover 540 according to the first embodiment in that there is no upper rising portion 541, side rising portions 542, 543, and the creepage distance for insulation is increased. Insulating paper upper part 536 and insulating paper side part 537 for securing are present.

  The insulating paper upper portion 536 is bent toward the positive-side capacitor terminal 506 side. Thereby, the exposed part of the positive electrode side capacitor terminal 506 can be covered, and insulation of the terminal can be ensured.

  With the insulating paper 535 according to the present embodiment, it is possible to secure insulation at a reduced cost.

  FIG. 26 is an external perspective view of an insulating cover 545 according to the third embodiment. The insulating cover 545 according to the present embodiment is different from the insulating cover 540 according to the first embodiment in that a side rising portion 544 raised in a direction opposite to the rising direction of the side rising portion 543 is provided. Is to be formed.

  The negative terminal rising portion 524 on the housing 12 side is covered with the side rising portion 544, and insulation between the inner wall of the housing 12 and the negative terminal rising portion 524 can be ensured.

  In any of the first to third embodiments, the inner wall of the housing 12, particularly the inner wall in the vicinity of the negative terminal rising part 524 and the positive terminal rising part 526, is subjected to insulation processing. Thus, insulation may be ensured. Specific examples of the insulating process include anodizing, and attaching an insulating sheet to the inner wall of the housing 12.

16 Lower case 500 Capacitor module 502 Capacitor module case 504A Negative electrode side capacitor terminal 506A Positive electrode side capacitor terminal 510 Negative electrode side connection terminal portion 511A Opening portion 512 Positive electrode side connection terminal portion 522 Filler 530 Discharge resistance 540A Insulation cover 549 Bolt hole

Claims (3)

A capacitor element;
A filler for sealing the capacitor element;
A first electrode terminal side rising portion electrically connected to the capacitor element and rising from the filler;
A second electrode terminal side rising portion electrically connected to the capacitor element and rising from the filler;
A first electrode side capacitor terminal connected to an end of the first electrode terminal side rising portion;
A second electrode side capacitor terminal connected to an end of the second electrode terminal side rising portion;
An insulating member disposed between the first electrode terminal side rising portion and the second electrode terminal side rising portion;
The second electrode side capacitor terminal is formed along a direction away from the first electrode side capacitor terminal,
The connection surface with the outside of the first electrode side capacitor terminal is formed lower than the connection surface with the outside of the second electrode side capacitor terminal,
The insulating member is formed by bending to the side where the first electrode side capacitor terminal is disposed,
The insulating member is an insulating cover formed of an insulating member;
The insulating cover includes an insulating cover main surface portion sandwiched between the first electrode terminal side rising portion and the second electrode terminal side rising portion, and an upper rising portion rising from an upper portion of the insulating cover main surface portion. Consists of,
Further, the insulating cover, the capacitor module, wherein the first electrode side capacitor terminals the upper rising portion Ru is disposed so as to cover a portion of the first electrode side capacitor terminals. The capacitor module according to claim 1,
The insulating cover further includes a side rising portion that rises from a side portion of the insulating cover main surface portion,
The side riser is a capacitor module formed so as to cover a part of the first electrode side capacitor terminal. The capacitor module according to claim 1,
The insulating cover further includes a side rising portion that rises from a side portion of the insulating cover main surface portion,
The side raised portion is a capacitor module formed so as to cover a part of the first electrode side capacitor terminal and a part of the second electrode side capacitor terminal.

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