JP6910498B1

JP6910498B1 - Busbar module and power converter using it

Info

Publication number: JP6910498B1
Application number: JP2020073259A
Authority: JP
Inventors: 小玉　勝久; 勝久小玉; 勇太瓜生; 陽一今城
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2020-04-16
Filing date: 2020-04-16
Publication date: 2021-07-28
Anticipated expiration: 2040-04-16
Also published as: JP2021170879A

Abstract

【課題】バスバーモジュールが備えた板金バスバーの温度上昇を抑制しつつ、小型化することができるバスバーモジュール及びそれを用いた電力変換装置を得ること。【解決手段】バスバーモジュールは、電気回路を構成する部品と接続される複数の板状の接続端部、及び複数の接続端部の間を接続する板状の導体部を有する板金バスバーと、導体部と一方の面が対向する板状部を有した板金部材と、板金バスバーと板金部材のそれぞれを取り囲む樹脂部材と、を備え、板状部の他方の面が樹脂部材から外部に露出すると共に、板金バスバーと板金部材とは樹脂部材で一体化されている。【選択図】図９PROBLEM TO BE SOLVED: To obtain a bus bar module capable of miniaturization while suppressing a temperature rise of a sheet metal bus bar provided in the bus bar module, and a power conversion device using the same. A bus bar module includes a sheet metal bus bar having a plurality of plate-shaped connecting ends connected to components constituting an electric circuit, and a plate-shaped conductor portion connecting between the plurality of connecting ends, and a conductor. A sheet metal member having a plate-shaped portion having a portion and one surface facing each other, and a resin member surrounding each of the sheet metal bus bar and the sheet metal member are provided, and the other surface of the plate-shaped portion is exposed to the outside from the resin member. , The sheet metal bus bar and the sheet metal member are integrated with a resin member. [Selection diagram] FIG. 9

Description

本願は、バスバーモジュール及びそれを用いた電力変換装置に関するものである。 The present application relates to a bus bar module and a power conversion device using the bus bar module.

電気自動車又はハイブリッド自動車のように、駆動源にモータが用いられている電動車両には、複数の電力変換装置が搭載されている。電力変換装置としては、商用の交流電源から直流電源に変換して高圧バッテリに充電する充電器、高圧バッテリの直流電源から補助機器用のバッテリの電圧（例えば１２Ｖ）に変換するＤＣ／ＤＣコンバータ、バッテリからの直流電力をモータへの交流電力に変換するインバータ等が挙げられる。電気自動車又はハイブリッド車に搭載される電力変換装置は、燃費の向上、車内空間の拡大、低コスト化等を目的として、小型化及び軽量化が求められている。そのため、電力変換装置を構成する各部品を、小型化及び軽量化することが重要となっている。 An electric vehicle such as an electric vehicle or a hybrid vehicle in which a motor is used as a drive source is equipped with a plurality of electric power conversion devices. The power converter includes a charger that converts a commercial AC power supply to a DC power supply and charges the high-voltage battery, and a DC / DC converter that converts the DC power supply of the high-pressure battery into the voltage of the battery for auxiliary equipment (for example, 12V). Examples thereof include an inverter that converts DC power from a battery into AC power to a motor. The power conversion device mounted on an electric vehicle or a hybrid vehicle is required to be downsized and lightened for the purpose of improving fuel efficiency, expanding the space inside the vehicle, reducing the cost, and the like. Therefore, it is important to reduce the size and weight of each component constituting the power conversion device.

電力変換装置を構成するトランス、リアクトル等の電磁誘導機器を小型化させる手法としては、これらの部品の駆動周波数を高周波化することが有効である。駆動周波数を高周波化することにより、トランス及びリアクトルを構成するコイルの巻数を少なくすることができる。また、駆動周波数を高周波化することにより、磁性材料であるコアの断面積を小さくすることができる。しかしながら、コイル及び各部品を接続する配線基板のパターンは駆動周波数を高周波化することで表皮効果の影響が顕著になり、高周波抵抗が増大して発熱量が増加する。したがって、駆動周波数の高周波化により、コイル及びパターンにおいて温度が著しく上昇するという課題があった。 As a method for miniaturizing electromagnetic induction devices such as transformers and reactors that make up a power conversion device, it is effective to increase the drive frequency of these components. By increasing the drive frequency, the number of turns of the coils constituting the transformer and the reactor can be reduced. Further, by increasing the drive frequency, the cross-sectional area of the core, which is a magnetic material, can be reduced. However, in the pattern of the wiring board connecting the coil and each component, the influence of the skin effect becomes remarkable by increasing the drive frequency, the high frequency resistance increases, and the amount of heat generated increases. Therefore, there is a problem that the temperature of the coil and the pattern rises remarkably due to the increase in the drive frequency.

また、近年、航続距離の増大を目的として、特に電気自動車に搭載された電池の容量を増加させる傾向が強まっている。そのため、商用の交流電源を直流変換及び変圧して電池に供給する役割を担う車載充電器においては、出力電力を増加させる要求が高まっている。車載充電器を高出力化する場合、入力側の商用交流電源からの電流量を増加させる必要がある。そのため、車載充電器を構成するトランス及びリアクトルのコイル、及び配線基板のパターンを流れる電流量が増加し、発熱量も増加する。小型化に加えて、車載充電器の高出力化によっても、コイル及びパターンにおいて温度が著しく上昇するという課題もあった。これら課題に対して、配線の抵抗成分である配線インダクタンスの低減を図ることでコイル及びパターンの温度上昇を抑制するために、複数の板状導体のバスバーをバスバーの厚さ方向に積層し、モールドで一体成形した構造が開示されている（例えば、特許文献１参照）。 Further, in recent years, there is an increasing tendency to increase the capacity of batteries mounted on electric vehicles in particular for the purpose of increasing the cruising range. Therefore, there is an increasing demand for increasing the output power of an in-vehicle charger that plays a role of converting and transforming a commercial AC power source into DC and supplying it to a battery. When increasing the output of an in-vehicle charger, it is necessary to increase the amount of current from the commercial AC power supply on the input side. Therefore, the amount of current flowing through the transformer and reactor coils constituting the vehicle-mounted charger and the pattern of the wiring board increases, and the amount of heat generated also increases. In addition to the miniaturization, there is also a problem that the temperature of the coil and the pattern rises remarkably due to the increase in the output of the in-vehicle charger. To solve these problems, in order to suppress the temperature rise of the coil and pattern by reducing the wiring inductance, which is the resistance component of the wiring, bus bars of a plurality of plate-shaped conductors are laminated in the thickness direction of the bus bar and molded. (See, for example, Patent Document 1).

特開２０１５−５６９７２号公報Japanese Unexamined Patent Publication No. 2015-56972

上記特許文献１においては、複数の板状導体のバスバーをバスバーの厚さ方向に積層しているため、配線の抵抗成分である配線インダクタンスの低減が図られ、コイル及びパターンの温度上昇を抑制することができる。しかしながら、複数のバスバーが積層されているため、冷却器で複数のバスバーの積層された面を冷却することは困難であり、積層により電力変換装置が大型化するという課題があった。積層されたバスバーの側面を冷却する場合においても、バスバーの積層された面が冷却器に対して直交するため、冷却器にバスバーの積層された面を冷却器に対向させた場合と同様に、電力変換装置が大型化するという課題があった。 In Patent Document 1, since the bus bars of a plurality of plate-shaped conductors are laminated in the thickness direction of the bus bars, the wiring inductance, which is a resistance component of the wiring, is reduced, and the temperature rise of the coil and the pattern is suppressed. be able to. However, since a plurality of bus bars are stacked, it is difficult to cool the stacked surfaces of the plurality of bus bars with a cooler, and there is a problem that the power conversion device becomes large due to the stacking. Even when cooling the side surfaces of the stacked busbars, the laminated surfaces of the busbars are orthogonal to the cooler, so that the laminated surfaces of the busbars face the cooler in the same manner as when the laminated surfaces of the busbars face the cooler. There is a problem that the power conversion device becomes large.

そこで、本願は、バスバーモジュールが備えた板金バスバーの温度上昇を抑制しつつ、小型化することができるバスバーモジュール及びそれを用いた電力変換装置を得ることを目的としている。 Therefore, an object of the present application is to obtain a bus bar module capable of miniaturization while suppressing a temperature rise of a sheet metal bus bar provided in the bus bar module and a power conversion device using the bus bar module.

本願に開示されるバスバーモジュールは、電気回路を構成する部品と接続される複数の板状の接続端部、及び複数の接続端部の間を接続する板状の導体部を有する板金バスバーと、導体部と一方の面が対向する板状部を有した板金部材と、板金バスバーと板金部材のそれぞれを取り囲む樹脂部材とを備え、板状部の他方の面が樹脂部材から外部に露出すると共に、板金バスバーと板金部材とは樹脂部材で一体化されているものである。 The busbar module disclosed in the present application includes a sheet metal busbar having a plurality of plate-shaped connecting ends connected to components constituting an electric circuit, and a plate-shaped conductor portion connecting between the plurality of connecting ends. A sheet metal member having a plate-shaped portion having a conductor portion and one surface facing each other and a resin member surrounding each of the sheet metal bus bar and the sheet metal member are provided, and the other surface of the plate-shaped portion is exposed to the outside from the resin member. , The sheet metal bus bar and the sheet metal member are integrated with a resin member.

本願に開示される電力変換装置は、複数の電気部品と、一方の面に複数の電気部品が並べて配置されている冷却器と、冷却器の一方の面と対向して配置されるバスバーモジュールと、冷却器の一方の面と対向して配置される、複数の回路部品が実装された回路基板とを備え、複数の電気部品は、バスバーモジュールが備えた複数の前記接続端部もしくは回路基板と接続され、バスバーモジュールが備えた複数の接続端部は、複数の電気部品もしくは回路基板と接続され、回路基板は、バスバーモジュールが備えた複数の接続端部もしくは複数の電気部品と接続されているものである。 The power conversion device disclosed in the present application includes a plurality of electric components, a cooler in which a plurality of electric components are arranged side by side on one surface, and a bus bar module arranged so as to face one surface of the cooler. A circuit board on which a plurality of circuit components are mounted, which is arranged so as to face one surface of the cooler, and the plurality of electric components may be provided with the plurality of connection ends or circuit boards provided in the bus bar module. The plurality of connection ends provided by the bus bar module are connected to a plurality of electric components or circuit boards, and the circuit board is connected to a plurality of connection ends or a plurality of electric components provided by the bus bar module. It is a thing.

本願に開示されるバスバーモジュールによれば、バスバーモジュールが備えた板金バスバーの導体部と一方の面が対向する板状部を有した板金部材の板状部の他方の面が樹脂部材から外部に露出すると共に、板金バスバーと板金部材とは樹脂部材で一体化されているため、板金バスバーに生じた熱が板金部材を介して放熱されるので、板金バスバーの温度上昇を抑制しつつ、バスバーモジュールを小型化することができる。 According to the bus bar module disclosed in the present application, the other surface of the plate-shaped portion of the sheet metal member having a plate-shaped portion in which one surface faces the conductor portion of the sheet metal bus bar provided in the bus bar module is outward from the resin member. Since the sheet metal bus bar and the sheet metal member are integrated with a resin member while being exposed, the heat generated in the sheet metal bus bar is dissipated through the sheet metal member, so that the bus bar module suppresses the temperature rise of the sheet metal bus bar. Can be miniaturized.

本願に開示される電力変換装置によれば、板金部材の板状部の他方の面が樹脂部材から外部に露出すると共に、板金バスバーと板金部材とは樹脂部材で一体化されているバスバーモジュールを備えているため、電力変換装置を小型化することができる。 According to the power conversion device disclosed in the present application, the other surface of the plate-shaped portion of the sheet metal member is exposed to the outside from the resin member, and the sheet metal bus bar and the sheet metal member are integrated with the resin member. Since it is provided, the power conversion device can be miniaturized.

実施の形態１に係る電力変換装置の構成の概略を示すブロック図である。It is a block diagram which shows the outline of the structure of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態１に係る電力変換装置のＤＣ／ＤＣコンバータ部の回路構成を示す図である。It is a figure which shows the circuit structure of the DC / DC converter part of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態１に係る電力変換装置の外観を示す斜視図である。It is a perspective view which shows the appearance of the power conversion apparatus which concerns on Embodiment 1. FIG. 図３のＡ−Ａ断面位置で切断した電力変換装置の断面図である。It is sectional drawing of the power conversion apparatus cut at the AA sectional position of FIG. 実施の形態１に係る電力変換装置の要部の分解斜視図である。It is an exploded perspective view of the main part of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態１に係る電力変換装置のバスバーモジュールの斜視図である。It is a perspective view of the bus bar module of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態１に係る電力変換装置のバスバーモジュールの斜視図である。It is a perspective view of the bus bar module of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態１に係る電力変換装置のバスバーモジュールの平面図である。It is a top view of the bus bar module of the power conversion apparatus which concerns on Embodiment 1. FIG. 図８のＢ−Ｂ断面位置で切断したバスバーモジュールの断面図である。It is sectional drawing of the bus bar module cut at the BB sectional position of FIG. 実施の形態１に係る電力変換装置のバスバーモジュールの要部の分解斜視図である。It is an exploded perspective view of the main part of the bus bar module of the power conversion apparatus which concerns on Embodiment 1. FIG. 実施の形態２に係る電力変換装置の断面図である。It is sectional drawing of the power conversion apparatus which concerns on Embodiment 2. FIG. 実施の形態２に係る電力変換装置の要部断面図である。It is sectional drawing of the main part of the power conversion apparatus which concerns on Embodiment 2. FIG.

以下、本願の実施の形態によるバスバーモジュール及びそれを用いた電力変換装置を図に基づいて説明する。なお、各図において同一、または相当部材、部位については同一符号を付して説明する。 Hereinafter, the bus bar module according to the embodiment of the present application and the power conversion device using the bus bar module will be described with reference to the drawings. In each figure, the same or corresponding members and parts will be described with the same reference numerals.

実施の形態１．
図１は実施の形態１に係る電力変換装置１の構成の概略を示すブロック図、図２は電力変換装置１のＤＣ／ＤＣコンバータ部４ａの回路構成を示す図、図３は電力変換装置１の外観を示す斜視図、図４は図３のＡ−Ａ断面位置で切断した電力変換装置１の断面図、図５は電力変換装置１の要部の分解斜視図、図６は電力変換装置１のバスバーモジュール２０の他方の側を示す斜視図、図７は電力変換装置１のバスバーモジュール２０の一方の側を示す斜視図、図８は電力変換装置１のバスバーモジュール２０の他方の側の平面図、図９は図８のＢ−Ｂ断面位置で切断したバスバーモジュール２０の断面図、図１０は電力変換装置１のバスバーモジュール２０の要部の分解斜視図である。図３は冷却器８の外周壁８ｂで囲まれた開口を覆うカバー９を取り除いて示した図であり、バスバーモジュール２０の他方の側は回路基板１５と対向する側とする。電力の変換を行う電力変換装置１は、モータを駆動源の一つとする電気自動車、もしくはハイブリット自動車等の車両に搭載されて用いられる。 Embodiment 1.
FIG. 1 is a block diagram showing an outline of the configuration of the power conversion device 1 according to the first embodiment, FIG. 2 is a diagram showing a circuit configuration of the DC / DC converter unit 4a of the power conversion device 1, and FIG. 3 is a power conversion device 1. 4 is a cross-sectional view of the power conversion device 1 cut at the AA cross-sectional position of FIG. 3, FIG. 5 is an exploded perspective view of a main part of the power conversion device 1, and FIG. 6 is a power conversion device. 1 is a perspective view showing the other side of the bus bar module 20 of 1, FIG. 7 is a perspective view showing one side of the bus bar module 20 of the power conversion device 1, and FIG. 8 is a perspective view showing the other side of the bus bar module 20 of the power conversion device 1. A plan view, FIG. 9 is a cross-sectional view of the bus bar module 20 cut at the BB cross-sectional position of FIG. 8, and FIG. 10 is an exploded perspective view of a main part of the bus bar module 20 of the power conversion device 1. FIG. 3 is a view showing the cooler 8 with the cover 9 covering the opening surrounded by the outer peripheral wall 8b removed, and the other side of the bus bar module 20 is the side facing the circuit board 15. The power conversion device 1 that converts electric power is used by being mounted on a vehicle such as an electric vehicle or a hybrid vehicle that uses a motor as one of the drive sources.

＜電力変換装置１の構成の概要＞
電力変換装置１は、図１に示すように、交流電源２から供給された電力を変換して負荷３に供給する。交流電源２からは、例えば商用の交流電力が供給される。変換された電力は例えば直流電力で、高圧バッテリもしくはモータ等の負荷３に供給される。負荷３が電気自動車の駆動用バッテリの場合、電力変換装置１は１００〜２００Ｖの商用の入力交流電圧を昇圧して３００〜４００Ｖ程度の直流電圧に変換する。電力変換装置１は、電力変換を行うパワー系主回路部４と、パワー系主回路部４の動作を制御する制御回路部５と、電力変換装置１の外部へのノイズの流出を抑制する入力フィルタ回路部６及び出力フィルタ回路部７とで構成される。 <Outline of configuration of power converter 1>
As shown in FIG. 1, the power conversion device 1 converts the power supplied from the AC power supply 2 and supplies it to the load 3. For example, commercial AC power is supplied from the AC power supply 2. The converted power is, for example, DC power, which is supplied to a load 3 such as a high-voltage battery or a motor. When the load 3 is a drive battery for an electric vehicle, the power converter 1 boosts a commercial input AC voltage of 100 to 200 V and converts it into a DC voltage of about 300 to 400 V. The power conversion device 1 includes a power system main circuit unit 4 that performs power conversion, a control circuit unit 5 that controls the operation of the power system main circuit unit 4, and an input that suppresses the outflow of noise to the outside of the power conversion device 1. It is composed of a filter circuit unit 6 and an output filter circuit unit 7.

＜ＤＣ／ＤＣコンバータ部４ａの回路構成の概要＞
パワー系主回路部４は、ＡＣ／ＤＣコンバータ部、ＤＣ／ＤＣコンバータ部４ａ、及び各コンバータ間に設けられたコンデンサ部を備える。以下、電力変換装置１の要部としてＤＣ／ＤＣコンバータ部４ａについて説明する。ＤＣ／ＤＣコンバータ部４ａは、図２に示すように、トランス２０１、整流回路部２０２、平滑回路部２０３、及びスイッチング回路部（図示せず）を備える。トランス２０１と整流回路部２０２との間、及び整流回路部２０２と平滑回路部２０３との間はパワー線２０５で接続される。ＤＣ／ＤＣコンバータ部４ａは、スイッチング回路部を介して交流電力をトランス２０１へ伝送する入力線２０６、及び平滑回路部２０３から出力フィルタ回路部７へ変換された電力を出力する出力線２０７を備える。 <Outline of circuit configuration of DC / DC converter unit 4a>
The power system main circuit unit 4 includes an AC / DC converter unit, a DC / DC converter unit 4a, and a capacitor unit provided between the converters. Hereinafter, the DC / DC converter unit 4a will be described as a main part of the power conversion device 1. As shown in FIG. 2, the DC / DC converter unit 4a includes a transformer 201, a rectifier circuit unit 202, a smoothing circuit unit 203, and a switching circuit unit (not shown). The transformer 201 and the rectifying circuit unit 202, and the rectifying circuit unit 202 and the smoothing circuit unit 203 are connected by a power line 205. The DC / DC converter unit 4a includes an input line 206 that transmits AC power to the transformer 201 via a switching circuit unit, and an output line 207 that outputs the power converted from the smoothing circuit unit 203 to the output filter circuit unit 7. ..

トランス２０１は、１次側コイル２０１ａと２次側コイル２０１ｂにより入力された電圧を昇圧して出力する変圧機能を備える。トランス２０１は、スイッチング回路部から入力された電圧を絶縁させながら電力変換装置１に接続された負荷３であるバッテリの電圧まで昇圧する。トランス２０１の１次側コイル２０１ａの巻数と２次側コイル２０１ｂの巻数の比に応じてトランス２０１の変圧比が決定される。この昇圧の例では、２次側コイル２０１ｂの巻数は１次側コイル２０１ａの巻数よりも多くなる様に設定される。 The transformer 201 has a transformer function of boosting and outputting the voltage input by the primary coil 201a and the secondary coil 201b. The transformer 201 boosts the voltage of the battery, which is the load 3 connected to the power conversion device 1, while insulating the voltage input from the switching circuit unit. The transformation ratio of the transformer 201 is determined according to the ratio of the number of turns of the primary coil 201a of the transformer 201 to the number of turns of the secondary coil 201b. In this boosting example, the number of turns of the secondary coil 201b is set to be larger than the number of turns of the primary coil 201a.

整流回路部２０２は、整流素子である複数のダイオード２０２ａを備える。ここでの整流回路部２０２は４つのダイオード２０２ａを有しているが、ダイオード２０２ａの個数はこれに限るものではない。整流回路部２０２は、トランス２０１の２次側コイル２０１ｂから出力された高電圧の交流を直流に変換する。平滑回路部２０３は、平滑リアクトル２０３ａと平滑コンデンサ（図示せず）を備える。平滑回路部２０３は、整流回路部２０２で整流された直流波形を平滑化して出力線２０７に出力する。 The rectifying circuit unit 202 includes a plurality of diodes 202a that are rectifying elements. The rectifier circuit unit 202 here has four diodes 202a, but the number of diodes 202a is not limited to this. The rectifier circuit unit 202 converts the high-voltage alternating current output from the secondary coil 201b of the transformer 201 into direct current. The smoothing circuit unit 203 includes a smoothing reactor 203a and a smoothing capacitor (not shown). The smoothing circuit unit 203 smoothes the DC waveform rectified by the rectifying circuit unit 202 and outputs it to the output line 207.

＜電力変換装置１の内部構成＞
電力変換装置１の内部構成について説明する。電力変換装置１は、ＤＣ／ＤＣコンバータ部４ａを構成する電気部品である複数のパワー系主回路部品と、一方の面である配置面８ｃに複数のパワー系主回路部品が並べて配置されている冷却器８と、配置面８ｃと対向して配置されるバスバーモジュール２０と、配置面８ｃと対向して配置され、複数の回路部品が実装された回路基板１５とを備える。複数のパワー系主回路部品、バスバーモジュール２０、及び回路基板１５を収容する電力変換装置１の筐体は、冷却器８と、冷却器８の配置面８ｃと対向して冷却器８の外周壁８ｂを覆うカバー９とから構成される。複数のパワー系主回路部品は、バスバーモジュール２０が備えた複数の接続端部１０１もしくは回路基板１５と接続される。バスバーモジュール２０が備えた複数の接続端部１０１は、複数のパワー系主回路部品もしくは回路基板１５と接続される。回路基板１５は、バスバーモジュール２０が備えた複数の接続端部１０１もしくはパワー系主回路部品の端子と接続される。 <Internal configuration of power converter 1>
The internal configuration of the power conversion device 1 will be described. In the power conversion device 1, a plurality of power system main circuit components, which are electrical components constituting the DC / DC converter unit 4a, and a plurality of power system main circuit components are arranged side by side on an arrangement surface 8c, which is one surface. It includes a cooler 8, a bus bar module 20 arranged to face the arrangement surface 8c, and a circuit board 15 arranged to face the arrangement surface 8c and on which a plurality of circuit components are mounted. The housing of the power conversion device 1 accommodating the plurality of power system main circuit components, the bus bar module 20, and the circuit board 15 is such that the cooler 8 and the outer peripheral wall of the cooler 8 face the arrangement surface 8c of the cooler 8. It is composed of a cover 9 that covers 8b. The plurality of power system main circuit components are connected to the plurality of connection end portions 101 or the circuit board 15 provided in the bus bar module 20. The plurality of connection end portions 101 included in the bus bar module 20 are connected to a plurality of power system main circuit components or circuit boards 15. The circuit board 15 is connected to a plurality of connection end portions 101 provided in the bus bar module 20 or terminals of power system main circuit components.

電力変換装置１は、高電圧、大電流を変換するパワー系主回路部品としてＰＦＣリアクトル２０４、トランス２０１、整流回路部２０２、平滑回路部２０３、ＡＣ／ＤＣコンバータ回路部（図示せず）、及びＤＣ／ＤＣコンバータ回路部（図示せず）を備える。トランス２０１、整流回路部２０２、平滑リアクトル２０３ａ、及びＰＦＣリアクトル２０４は、図４に示すように、冷却器８の配置面８ｃに実装される。ここでは、冷却器８の配置面８ｃに沿って、配置方向の一方側から他方側に向かってトランス２０１、整流回路部２０２、平滑リアクトル２０３ａ、及びＰＦＣリアクトル２０４が順に並べて設けられ、整流回路部２０２は冷却器８の配置面８ｃからの突出高さがトランス２０１及び平滑リアクトル２０３ａよりも低い。整流回路部２０２は２次側ダイオード金属基板モジュール、ＡＣ／ＤＣコンバータ回路部はＡＣ／ＤＣ金属基板モジュール、ＤＣ／ＤＣコンバータ回路部はＤＣ／ＤＣ金属基板モジュールの形態で電力変換装置１に用いられる。図５では省略して配置面８ｃを平面で示しているが、配置面８ｃには図４に示すようにパワー系主回路部品のそれぞれが配置される凹部が形成されている。凹部のそれぞれは、配置されるパワー系主回路部品の大きさに合わせた形状で形成される。凹部を形成することでパワー系主回路部品が配置面８ｃ上に容易に位置決めされて配置されるため、電力変換装置１の生産性を向上することができる。 The power conversion device 1 includes a PFC reactor 204, a transformer 201, a rectifier circuit unit 202, a smoothing circuit unit 203, an AC / DC converter circuit unit (not shown), and an AC / DC converter circuit unit (not shown) as power system main circuit components that convert high voltage and large current. A DC / DC converter circuit unit (not shown) is provided. The transformer 201, the rectifier circuit unit 202, the smoothing reactor 203a, and the PFC reactor 204 are mounted on the arrangement surface 8c of the cooler 8 as shown in FIG. Here, the transformer 201, the rectifier circuit unit 202, the smoothing reactor 203a, and the PFC reactor 204 are provided side by side in this order from one side to the other side in the arrangement direction along the arrangement surface 8c of the cooler 8. In 202, the protruding height of the cooler 8 from the arrangement surface 8c is lower than that of the transformer 201 and the smoothing reactor 203a. The rectifier circuit unit 202 is used in the power conversion device 1 in the form of a secondary diode metal substrate module, the AC / DC converter circuit unit in the form of an AC / DC metal substrate module, and the DC / DC converter circuit unit in the form of a DC / DC metal substrate module. .. Although the arrangement surface 8c is omitted in FIG. 5 and shown in a plane, the arrangement surface 8c is formed with recesses in which each of the power system main circuit components is arranged as shown in FIG. Each of the recesses is formed in a shape that matches the size of the power system main circuit component to be arranged. By forming the recess, the power system main circuit component is easily positioned and arranged on the arrangement surface 8c, so that the productivity of the power conversion device 1 can be improved.

トランス２０１、整流回路部２０２、平滑リアクトル２０３ａ、及びＰＦＣリアクトル２０４は、カバー９の方向に突出した端子を備える。これらのパワー系主回路部品が備えた端子の一部は、図６に示したバスバーモジュール２０の接続端部１０１ａ１、１０１ｂ１、１０１ｄ１、１０１ｃ１、１０１ｆ２、１０１ｇ１、１０１ｈ１と、例えばＴｉＧ溶接にて接合される。接続端部１０１ａ１、１０１ｂ１、１０１ｄ１、１０１ｃ１、１０１ｆ２、１０１ｇ１、１０１ｈ１とパワー系主回路部品の端子との接続部は、樹脂カバー１６で覆われる。樹脂カバー１６は、図５に示すように、バスバーモジュール２０と回路基板１５との間に設けられる。接続部に樹脂カバー１６を被せることで、接続部と回路基板１５との間の絶縁を確保しつつ、接続部と回路基板１５との距離を短縮することができる。 The transformer 201, the rectifier circuit unit 202, the smoothing reactor 203a, and the PFC reactor 204 include terminals protruding in the direction of the cover 9. Some of the terminals provided by these power system main circuit components are joined to the connection ends 101a1, 101b1, 101d1, 101c1, 101f2, 101g1, 101h1 of the bus bar module 20 shown in FIG. 6, for example, by TiG welding. NS. The connection portion between the connection end portions 101a1, 101b1, 101d1, 101c1, 101f2, 101g1, 101h1 and the terminals of the power system main circuit component is covered with the resin cover 16. As shown in FIG. 5, the resin cover 16 is provided between the bus bar module 20 and the circuit board 15. By covering the connecting portion with the resin cover 16, the distance between the connecting portion and the circuit board 15 can be shortened while ensuring the insulation between the connecting portion and the circuit board 15.

回路基板１５は、配置面８ｃから離間して、例えばねじ止めによりバスバーモジュール２０に設置される。回路基板１５には制御回路部５が設けられ、回路基板１５はパワー系主回路部品等で構成されるパワー系主回路部４の動作を制御する。回路基板１５は、ＰＦＣリアクトル２０４と、ＡＣ／ＤＣコンバータ回路部と、リンクコンデンサ（図示せず）とを接続する配線を備える。回路基板１５が備える配線はこれらの電気部品を接続する配線に限られず、他のパワー系主回路部品及びバスバーモジュール２０を接続する配線も含まれる。回路基板１５は、図３に示すように、スルーホール１５ａ、１５ｂ等の複数のスルーホールを備える。回路基板１５と接続されるパワー系主回路部品が備える端子、及びバスバーモジュール２０が備える接続端部１０１がスルーホールに挿入され、半田付けされることで、パワー系主回路部品及びバスバーモジュール２０と配線とが接続される。例えば、スルーホール１５ａを介してＰＦＣリアクトル２０４の端子２０４ａと回路基板１５の配線とは接続される。また、スルーホール１５ｂを介してバスバーモジュール２０が備えた接続端部１０１ｈ２、１０１ｇ２と回路基板１５の配線とは接続される。この接続により、平滑リアクトル２０３ａと出力フィルタ回路部７（図示せず）とが接続される。 The circuit board 15 is separated from the arrangement surface 8c and installed on the bus bar module 20 by, for example, screwing. A control circuit unit 5 is provided on the circuit board 15, and the circuit board 15 controls the operation of the power system main circuit unit 4 composed of power system main circuit components and the like. The circuit board 15 includes wiring for connecting the PFC reactor 204, the AC / DC converter circuit unit, and the link capacitor (not shown). The wiring provided in the circuit board 15 is not limited to the wiring for connecting these electric components, but also includes the wiring for connecting other power system main circuit components and the bus bar module 20. As shown in FIG. 3, the circuit board 15 includes a plurality of through holes such as through holes 15a and 15b. The terminals included in the power system main circuit component connected to the circuit board 15 and the connection end 101 provided in the bus bar module 20 are inserted into the through holes and soldered to the power system main circuit components and the bus bar module 20. The wiring is connected. For example, the terminal 204a of the PFC reactor 204 and the wiring of the circuit board 15 are connected via the through hole 15a. Further, the connection ends 101h2 and 101g2 provided in the bus bar module 20 are connected to the wiring of the circuit board 15 via the through hole 15b. By this connection, the smoothing reactor 203a and the output filter circuit unit 7 (not shown) are connected.

冷却器８は、図５に示すように、直方体状の本体部８ａ、及び本体部８ａの外周に沿って本体部８ａの一方の面である配置面８ｃから立設した外周壁８ｂから構成される。冷却器８の本体部８ａの他方の面には、図４に示すように、冷媒１１が流れる冷却水路８ｄが形成される。冷却水路８ｄは、水路カバー１０で覆われて密閉されている。配置面８ｃに実装されたトランス２０１、整流回路部２０２、平滑回路部２０３、及びＰＦＣリアクトル２０４は、配置面８ｃ及び外周壁８ｂを介して冷却水路８ｄを流れる冷媒１１により冷却される。冷媒１１が流れる冷却水路８ｄを設けることで、実装されたこれらのパワー系主回路部品の発熱を抑制することができる。また、冷却器８の本体部８ａの他方の面の側に冷却水路８ｄを設けることで、冷却面となる配置面８ｃを広範囲に確保することができる。そのため、配置面８ｃに実装されたパワー系主回路部品の放熱面積を十分確保できるとともに、パワー系主回路部品の配置の自由度が向上する。 As shown in FIG. 5, the cooler 8 is composed of a rectangular parallelepiped main body 8a and an outer peripheral wall 8b erected from an arrangement surface 8c which is one surface of the main body 8a along the outer circumference of the main body 8a. NS. As shown in FIG. 4, a cooling water channel 8d through which the refrigerant 11 flows is formed on the other surface of the main body 8a of the cooler 8. The cooling water channel 8d is covered with a water channel cover 10 and sealed. The transformer 201, the rectifying circuit unit 202, the smoothing circuit unit 203, and the PFC reactor 204 mounted on the arrangement surface 8c are cooled by the refrigerant 11 flowing through the cooling water channel 8d through the arrangement surface 8c and the outer peripheral wall 8b. By providing the cooling water channel 8d through which the refrigerant 11 flows, it is possible to suppress heat generation of these mounted power system main circuit components. Further, by providing the cooling water channel 8d on the side of the other surface of the main body 8a of the cooler 8, the arrangement surface 8c serving as the cooling surface can be secured in a wide range. Therefore, a sufficient heat dissipation area of the power system main circuit component mounted on the arrangement surface 8c can be sufficiently secured, and the degree of freedom in arrangement of the power system main circuit component is improved.

外周壁８ｂで囲まれた開口は、図４に示すように、配置面８ｃと対向して設けられたカバー９で覆われる。カバー９は、例えば金属で作製される。カバー９で開口を覆うことで、電力変換装置１の内部を防水及び防塵し、電磁波の干渉を防止することができる。 As shown in FIG. 4, the opening surrounded by the outer peripheral wall 8b is covered with a cover 9 provided so as to face the arrangement surface 8c. The cover 9 is made of, for example, metal. By covering the opening with the cover 9, the inside of the power conversion device 1 can be made waterproof and dustproof, and interference of electromagnetic waves can be prevented.

＜バスバーモジュール２０の構成と配置＞
本願の要部であるバスバーモジュール２０について説明する。バスバーモジュール２０は、パワー系主回路部品と回路基板１５とを接続する接続部材である。バスバーモジュール２０は、図９に示すように、板金バスバー１００、板金部材１１０、及び板金バスバー１００と板金部材１１０のそれぞれを取り囲む樹脂部材１２０を備える。板金バスバー１００は、図１０に示すように、電気回路を構成する部品であるパワー系主回路部品または回路基板１５と接続される複数の板状の接続端部１０１、及び複数の接続端部１０１の間を接続する板状の導体部１０２を有する。板金部材１１０は、導体部１０２と一方の面が対向する板状部１１１を有する。板金バスバー１００は、導電性が良好で熱伝導率の高い銅または銅合金などの金属で作製される。板金部材１１０は、熱伝導率の高い銅または銅合金などの金属で作製される。板金部材１１０の板状部１１１の他方の面は、図８に示すように、樹脂部材１２０から外部に複数の箇所で露出している。バスバーモジュール２０は、さらにナット１１５、及びブッシュ１１６を備える。ナット１１５及びブッシュ１１６は、回路基板１５を固定して締結するために用いられる。板金バスバー１００、板金部材１１０、ナット１１５、及びブッシュ１１６は、樹脂部材１２０で一体化されている。 <Configuration and arrangement of bus bar module 20>
The bus bar module 20 which is a main part of the present application will be described. The bus bar module 20 is a connecting member that connects the power system main circuit component and the circuit board 15. As shown in FIG. 9, the bus bar module 20 includes a sheet metal bus bar 100, a sheet metal member 110, and a resin member 120 that surrounds each of the sheet metal bus bar 100 and the sheet metal member 110. As shown in FIG. 10, the sheet metal bus bar 100 includes a plurality of plate-shaped connection end portions 101 connected to a power system main circuit component or a circuit board 15 which are components constituting an electric circuit, and a plurality of connection end portions 101. It has a plate-shaped conductor portion 102 that connects between the two. The sheet metal member 110 has a plate-shaped portion 111 whose one surface faces the conductor portion 102. The sheet metal bus bar 100 is made of a metal such as copper or a copper alloy having good conductivity and high thermal conductivity. The sheet metal member 110 is made of a metal such as copper or a copper alloy having high thermal conductivity. As shown in FIG. 8, the other surface of the plate-shaped portion 111 of the sheet metal member 110 is exposed to the outside from the resin member 120 at a plurality of locations. The bus bar module 20 further includes a nut 115 and a bush 116. The nut 115 and the bush 116 are used to fix and fasten the circuit board 15. The sheet metal bus bar 100, the sheet metal member 110, the nut 115, and the bush 116 are integrated by the resin member 120.

バスバーモジュール２０は、パワー系主回路部品と回路基板１５との間に配置されている。バスバーモジュール２０を冷却器８に実装する際は、図５に示すように、バスバーモジュール２０の位置決めピン２０ａを冷却器８の位置決め穴８ｅに挿入することで位置決めされる。ここでは、図４に示すように、トランス２０１、整流回路部２０２、及び平滑リアクトル２０３ａに対向して設けられたバスバーモジュール２０は、整流回路部２０２に対向している部分が、トランス２０１に対向している部分及び平滑リアクトル２０３ａに対向している部分よりも冷却器８の配置面８ｃに近くなるように、整流回路部２０２の配置方向の両側部分に段差が形成されている。バスバーモジュール２０をパワー系主回路部品と回路基板１５との間に配置させて、バスバーモジュール２０によりパワー系主回路部品と回路基板１５とを接続することで、高電圧及び大電流の伝送を回路基板１５のパターンだけで行うのではなくバスバーモジュール２０を立体配線して行うことができる。高電圧及び大電流の伝送を回路基板１５のパターンだけで行わないため、回路基板１５の面積の削減により電力変換装置１の平面積を削減することができ、電力変換装置１を小型化することができる。また、バスバーモジュール２０に段差を設けることで配置面８ｃに配置されたパワー系主回路部品の配置面８ｃからの突出高さの高低差を吸収することができ、パワー系主回路部品と回路基板１５との間の絶縁距離を短縮することができる。また、回路基板１５の側に高さの高い回路部品を設けることができる。 The bus bar module 20 is arranged between the power system main circuit component and the circuit board 15. When the bus bar module 20 is mounted on the cooler 8, as shown in FIG. 5, the bus bar module 20 is positioned by inserting the positioning pin 20a of the bus bar module 20 into the positioning hole 8e of the cooler 8. Here, as shown in FIG. 4, in the bus bar module 20 provided so as to face the transformer 201, the rectifier circuit unit 202, and the smoothing reactor 203a, the portion facing the rectifier circuit unit 202 faces the transformer 201. Steps are formed on both side portions of the rectifier circuit unit 202 in the arrangement direction so as to be closer to the arrangement surface 8c of the cooler 8 than the portion facing the smoothing reactor 203a and the portion facing the smoothing reactor 203a. By arranging the bus bar module 20 between the power system main circuit component and the circuit board 15 and connecting the power system main circuit component and the circuit board 15 by the bus bar module 20, high voltage and large current transmission can be circuited. The bus bar module 20 can be three-dimensionally wired, not only by the pattern of the substrate 15. Since the transmission of high voltage and large current is not performed only by the pattern of the circuit board 15, the flat area of the power conversion device 1 can be reduced by reducing the area of the circuit board 15, and the power conversion device 1 can be miniaturized. Can be done. Further, by providing a step on the bus bar module 20, it is possible to absorb the height difference of the protrusion height of the power system main circuit component arranged on the arrangement surface 8c from the arrangement surface 8c, and the power system main circuit component and the circuit board can be absorbed. The insulation distance between 15 and 15 can be shortened. Further, a circuit component having a high height can be provided on the side of the circuit board 15.

＜板金部材１１０＞
バスバーモジュール２０は、板金部材１１０として３つの板金部材１１０ａ、１１０ｂ、１１０ｃを備える。板金部材１１０は、板金部材１１０が備えた板状部１１１の一方の面で板金バスバー１００の導体部１０２と対向する。板金部材１１０は、板金部材１１０が備えた板状部１１１の他方の面が樹脂部材１２０から外部に露出している。板金部材１１０は、バスバーモジュール２０において回路基板１５の側に配置されている。板状部１１１が導体部１０２に対向しているため、板金バスバー１００で発生した熱は板金部材１１０を介して効率良く放熱される。板金部材１１０は板状であるため、バスバーモジュール２０の厚みを大きくすることなく板金バスバー１００で発生した熱を放熱することができる。板状部１１１の他方の面が樹脂部材１２０から外部に露出しているため、板金部材１１０は効率良く放熱することができる。板金部材１１０が回路基板１５の側に配置されているため、回路基板１５及び回路基板１５に実装された制御系の回路部品が板金バスバー１００で発生した熱で煽られることがなく、電力変換装置１は安定して動作することができる。 <Sheet metal member 110>
The bus bar module 20 includes three sheet metal members 110a, 110b, and 110c as sheet metal members 110. The sheet metal member 110 faces the conductor portion 102 of the sheet metal bus bar 100 on one surface of the plate-shaped portion 111 provided by the sheet metal member 110. In the sheet metal member 110, the other surface of the plate-shaped portion 111 included in the sheet metal member 110 is exposed to the outside from the resin member 120. The sheet metal member 110 is arranged on the side of the circuit board 15 in the bus bar module 20. Since the plate-shaped portion 111 faces the conductor portion 102, the heat generated in the sheet metal bus bar 100 is efficiently dissipated through the sheet metal member 110. Since the sheet metal member 110 has a plate shape, the heat generated by the sheet metal bus bar 100 can be dissipated without increasing the thickness of the bus bar module 20. Since the other surface of the plate-shaped portion 111 is exposed to the outside from the resin member 120, the sheet metal member 110 can efficiently dissipate heat. Since the sheet metal member 110 is arranged on the side of the circuit board 15, the circuit board 15 and the circuit components of the control system mounted on the circuit board 15 are not fanned by the heat generated by the sheet metal bus bar 100, and the power conversion device. 1 can operate stably.

板金部材１１０の一方の面の側で、図７に示すように、板金部材１１０の一部分である冷却部１１２が樹脂部材１２０から露出している。冷却部１１２と冷却器８の外周壁８ｂとは接している。冷却部１１２ａ、１１２ｂは、図５に示した外周壁８ｂに設けられた接触部８ｆとそれぞれ接する。冷却部１１２と冷却器８の外周壁８ｂとが接することで、板金バスバー１００で発生した熱を冷却器８に板金部材１１０を介して放熱することができる。冷却部１１２を冷却部１１２に隣接した外周壁８ｂと接触させることで、容易に放熱することができる。なお、冷却部１１２が接する箇所は外周壁８ｂに限るものではなく、例えば熱伝導率の高い金属製の接触部材を介して冷却器８の本体部８ａと冷却部１１２とが接しても構わない。 On one side of the sheet metal member 110, as shown in FIG. 7, the cooling portion 112, which is a part of the sheet metal member 110, is exposed from the resin member 120. The cooling unit 112 and the outer peripheral wall 8b of the cooler 8 are in contact with each other. The cooling portions 112a and 112b are in contact with the contact portions 8f provided on the outer peripheral wall 8b shown in FIG. 5, respectively. When the cooling unit 112 and the outer peripheral wall 8b of the cooler 8 are in contact with each other, the heat generated by the sheet metal bus bar 100 can be dissipated to the cooler 8 via the sheet metal member 110. By bringing the cooling unit 112 into contact with the outer peripheral wall 8b adjacent to the cooling unit 112, heat can be easily dissipated. The location where the cooling unit 112 comes into contact is not limited to the outer peripheral wall 8b, and for example, the main body 8a of the cooler 8 and the cooling unit 112 may come into contact with each other via a metal contact member having high thermal conductivity. ..

＜板金バスバー１００＞
バスバーモジュール２０は複数の板金バスバー１００ａ、１００ｂ、１００ｃ、１００ｄ、１００ｅ、１００ｆ、１００ｇ、１００ｈを備える。板金バスバー１００ａと１００ｃ、板金バスバー１００ｂと１００ｄ、板金バスバー１００ｅと１００ｆ、及び板金バスバー１００ｇと１００ｈのそれぞれが備えた導体部１０２は、間隔を空けて同一平面に設けられている。導体部１０２を同一平面に設けることで、バスバーモジュール２０の厚みの均一化が図られ、バスバーモジュール２０を薄型化することができる。また、導体部１０２を同一平面に設けることで、導体部１０２と板金部材１１０との距離の均一化が図られ、板金部材１１０を介した放熱の経路の均一化を図ることができる。 <Sheet metal bus bar 100>
The bus bar module 20 includes a plurality of sheet metal bus bars 100a, 100b, 100c, 100d, 100e, 100f, 100g, 100h. The conductor portions 102 provided by the sheet metal bus bars 100a and 100c, the sheet metal bus bars 100b and 100d, the sheet metal bus bars 100e and 100f, and the sheet metal bus bars 100g and 100h are provided on the same plane at intervals. By providing the conductor portion 102 on the same plane, the thickness of the bus bar module 20 can be made uniform, and the bus bar module 20 can be made thinner. Further, by providing the conductor portion 102 on the same plane, the distance between the conductor portion 102 and the sheet metal member 110 can be made uniform, and the heat dissipation path through the sheet metal member 110 can be made uniform.

板金バスバー１００ｃと１００ｆとは、図９に示すように、樹脂部材１２０を介して積層されている。複数の板金バスバー１００を交差させて積層する場合、樹脂部材１２０を介して積層させることで、積層した板金バスバー１００と板金バスバー１００との間の絶縁を容易に確保することができる。また、バスバーモジュール２０の厚みを大きくすることなく絶縁を容易に確保することができる。 As shown in FIG. 9, the sheet metal bus bars 100c and 100f are laminated via the resin member 120. When a plurality of sheet metal bus bars 100 are crossed and laminated, the insulation between the laminated sheet metal bus bar 100 and the sheet metal bus bar 100 can be easily ensured by laminating via the resin member 120. In addition, insulation can be easily ensured without increasing the thickness of the bus bar module 20.

＜接続端部１０１＞
板金バスバー１００の接続端部１０１は、図６または図７に示すように、樹脂部材１２０から外部に露出している。接続端部１０１を外部に露出させることで、接続端部１０１とパワー系主回路部品または回路基板１５とを容易に接続することができる。なお、接続端部１０１を外部に露出させず、接続端部１０１と他の部品と接続した後に接続箇所を含めて樹脂部材１２０で板金バスバー１００と板金部材１１０とを封止しても構わない。 <Connection end 101>
As shown in FIG. 6 or 7, the connection end 101 of the sheet metal bus bar 100 is exposed to the outside from the resin member 120. By exposing the connection end 101 to the outside, the connection end 101 can be easily connected to the power system main circuit component or the circuit board 15. The sheet metal bus bar 100 and the sheet metal member 110 may be sealed with the resin member 120 including the connection portion after the connection end portion 101 is connected to other parts without exposing the connection end portion 101 to the outside. ..

接続端部１０１は、図１０に示すように、導体部１０２に対して直角に折り曲げられている。導体部１０２を折り曲げて設けることで、バスバーモジュール２０を小型化することができる。また、バスバーモジュール２０と対向して設けられるパワー系主回路部品または回路基板１５と容易に接続することができる。なお、接続端部１０１と接続される端子の配置によっては、接続端部１０１を直角に折り曲げずに設けて他の端子と接続しても構わない。 As shown in FIG. 10, the connection end portion 101 is bent at a right angle to the conductor portion 102. The bus bar module 20 can be miniaturized by bending the conductor portion 102. Further, it can be easily connected to the power system main circuit component or the circuit board 15 provided so as to face the bus bar module 20. Depending on the arrangement of the terminals connected to the connection end 101, the connection end 101 may be provided without being bent at a right angle and connected to other terminals.

板金バスバー１００ａ、１００ｃ、１００ｅ、１００ｆの両側の接続端部１０１、及び板金バスバー１００ｂ、１００ｄ、１００ｇ、１００ｈの片側の接続端部１０１ｂ１、１０１ｄ１、１０１ｇ１、１０１ｈ１において、接続端部１０１と導体部１０２との間の折り曲げ箇所に隣接した導体部１０２の部分が樹脂部材１２０から外部に露出している。隣接した導体部１０２の部分を樹脂部材１２０から外部に露出させることで、板金バスバー１００を樹脂部材１２０でインサート成形する際、成形金型で板金バスバー１００の接続端部１０１と隣接した導体部１０２の部分の双方を確実に保持することができる。双方を確実に保持できるため、接続端部１０１の成形精度を向上させることができる。また、接続端部１０１と導体部１０２との間の折り曲げ箇所を樹脂部材１２０で封止している箇所においては、接続端部１０１に近接する外周壁８ｂ及び配置面８ｃとの絶縁が確保され、また近接する電気部品との距離を短縮することができる。 In the connection end 101 on both sides of the sheet metal bus bars 100a, 100c, 100e, 100f, and the connection ends 101b1, 101d1, 101g1, 101h1 on one side of the sheet metal bus bars 100b, 100d, 100g, 100h, the connection end 101 and the conductor portion 102 The portion of the conductor portion 102 adjacent to the bent portion between the resin member 120 is exposed to the outside from the resin member 120. By exposing the portion of the adjacent conductor portion 102 to the outside from the resin member 120, when the sheet metal bus bar 100 is insert-molded by the resin member 120, the conductor portion 102 adjacent to the connection end portion 101 of the sheet metal bus bar 100 is formed by the molding die. Both parts of can be reliably held. Since both can be reliably held, the molding accuracy of the connection end 101 can be improved. Further, at the portion where the bent portion between the connection end portion 101 and the conductor portion 102 is sealed by the resin member 120, insulation from the outer peripheral wall 8b and the arrangement surface 8c close to the connection end portion 101 is ensured. Also, the distance to the adjacent electrical parts can be shortened.

接続端部１０１ｇ２、１０１ｈ２は、回路基板１５が備えたスルーホールを介して回路基板１５と、例えば半田付けにて接続される。他の接続端部１０１は、パワー系主回路部品が備えた端子と、例えばＴｉＧ溶接にて接合される。このように接続端部１０１とパワー系主回路部品及び回路基板１５とを接続することで、バスバー同士をネジで締結する構造もしくはラグ端子を基板に実装してラグ端子を介して接合する構造に比べて、実装面積を削減することができる。 The connection ends 101g2 and 101h2 are connected to the circuit board 15 via, for example, soldering through holes provided in the circuit board 15. The other connection end 101 is joined to the terminal provided in the power system main circuit component by, for example, TiG welding. By connecting the connection end 101, the power system main circuit component, and the circuit board 15 in this way, the structure is such that the bus bars are fastened with screws or the lug terminals are mounted on the board and joined via the lug terminals. In comparison, the mounting area can be reduced.

接続端部１０１ｇ２、１０１ｈ２において、接続端部１０１の幅が接続端部１０１の終端の方向に縮小されている。接続端部１０１の幅を縮小することで、回路基板１５のスルーホールの穴径を小型にすることができる。また、接続端部１０１の熱容量が小さくなるので接続端部１０１と回路基板１５のランドとを接続する半田が溶融しやすくなるため、接続端部１０１の半田付け性を向上させることができる。なお、ある程度の幅を有する程度に接続端部１０１の幅の縮小させた場合、大電力印加時の接続端部１０１における抵抗増加を抑制することができる。 At the connection end portions 101g2 and 101h2, the width of the connection end portion 101 is reduced in the direction of the end of the connection end portion 101. By reducing the width of the connection end 101, the hole diameter of the through hole of the circuit board 15 can be reduced. Further, since the heat capacity of the connection end 101 is reduced, the solder connecting the connection end 101 and the land of the circuit board 15 is easily melted, so that the solderability of the connection end 101 can be improved. When the width of the connection end 101 is reduced to such an extent that it has a certain width, it is possible to suppress an increase in resistance at the connection end 101 when a large amount of power is applied.

＜導体部１０２＞
板金バスバー１００ｆの導体部１０２ｆは、図９に示すように、折り曲げられて段差が形成された段差部１０３を設けている。段差部１０３は、図１０に示すように、板金バスバー１００ａ、１００ｃ、１００ｅにも設けられる。導体部１０２に段差部１０３を設けたことで、接続端部１０１の高さを容易に変えることができる。接続端部１０１の高さを変えることで、冷却器８の配置面８ｃからの突出高さがトランス２０１及び平滑リアクトル２０３ａよりも低い整流回路部２０２の端子とも容易に接続することができる。 <Conductor portion 102>
As shown in FIG. 9, the conductor portion 102f of the sheet metal bus bar 100f is provided with a step portion 103 which is bent to form a step. As shown in FIG. 10, the step portion 103 is also provided on the sheet metal bus bars 100a, 100c, and 100e. By providing the step portion 103 in the conductor portion 102, the height of the connection end portion 101 can be easily changed. By changing the height of the connection end 101, it can be easily connected to the terminals of the rectifier circuit unit 202 whose protrusion height from the arrangement surface 8c of the cooler 8 is lower than that of the transformer 201 and the smoothing reactor 203a.

＜樹脂部材１２０＞
板金バスバー１００と板金部材１１０のそれぞれを取り囲む樹脂部材１２０は、板金バスバー１００と板金部材１１０とを一体化している。樹脂部材１２０は板金バスバー１００と板金部材１１０のそれぞれを取り囲んで一体化しているため、板金バスバー１００の各々の間、及び板金バスバー１００と板金部材１１０との間の絶縁を確保することができる。また、板金バスバー１００及び板金部材１１０に近接して配置された部品との絶縁を保つことができる。 <Resin member 120>
The resin member 120 surrounding each of the sheet metal bus bar 100 and the sheet metal member 110 integrates the sheet metal bus bar 100 and the sheet metal member 110. Since the resin member 120 surrounds and integrates each of the sheet metal bus bar 100 and the sheet metal member 110, it is possible to secure insulation between each of the sheet metal bus bar 100 and between the sheet metal bus bar 100 and the sheet metal member 110. Further, it is possible to maintain the insulation from the parts arranged in the vicinity of the sheet metal bus bar 100 and the sheet metal member 110.

＜貫通孔１１７＞
板金バスバー１００の導体部１０２及び板金部材１１０には、貫通孔１１７を設けている。貫通孔１１７を設けることで、バスバーモジュール２０を樹脂部材１２０で封止する際、樹脂部材１２０が回り込みにくい板金バスバー１００と板金部材１１０との間にも樹脂部材１２０が充填されやすくなる。樹脂部材１２０の充填されない箇所の発生が抑制されるため、生産性の高いバスバーモジュール２０を作製することができる。 <Through hole 117>
Through holes 117 are provided in the conductor portion 102 and the sheet metal member 110 of the sheet metal bus bar 100. By providing the through hole 117, when the bus bar module 20 is sealed with the resin member 120, the resin member 120 can be easily filled between the sheet metal bus bar 100 and the sheet metal member 110 where the resin member 120 is difficult to wrap around. Since the occurrence of unfilled portions of the resin member 120 is suppressed, the bus bar module 20 with high productivity can be manufactured.

導体部１０２及び板金部材１１０はそれぞれ２つの貫通孔１１７を備え、導体部１０２の貫通孔１１７と板金部材１１０の貫通孔１１７とは、図１０の一点鎖線で示すように導体部１０２の表面に直交する方向に見て重なる位置に設けられている。導体部１０２及び板金部材１１０の双方に設けた貫通孔１１７を導体部１０２の表面に直交する方向に見て重なる位置に設けたため、板金バスバー１００と板金部材１１０を樹脂部材１２０で一体成形する際に双方の貫通孔１１７にピンを挿入することで、板金バスバー１００と板金部材１１０の回り止めができ、板金バスバー１００と板金部材１１０の水平方向の位置精度を向上することができる。また、板金バスバー１００と板金部材１１０を樹脂部材１２０で一体成形する際に貫通孔１１７に段付きピンを挿入して段差部分で板金バスバー１００を押さえることで、板金バスバー１００の水平方向の位置精度、及び上下方向の位置精度を向上させることができる。また、板金部材１１０にのみ貫通孔１１７を設けて板金バスバー１００の片面をピンで押さえた場合、板金バスバー１００と板金部材１１０との間隔を一定に保つことができる。 The conductor portion 102 and the sheet metal member 110 each have two through holes 117, and the through holes 117 of the conductor portion 102 and the through holes 117 of the sheet metal member 110 are formed on the surface of the conductor portion 102 as shown by the alternate long and short dash line in FIG. It is provided at an overlapping position when viewed in the orthogonal direction. Since the through holes 117 provided in both the conductor portion 102 and the sheet metal member 110 are provided at overlapping positions when viewed in a direction orthogonal to the surface of the conductor portion 102, when the sheet metal bus bar 100 and the sheet metal member 110 are integrally molded by the resin member 120. By inserting a pin into both through holes 117, the sheet metal bus bar 100 and the sheet metal member 110 can be prevented from rotating, and the horizontal positional accuracy of the sheet metal bus bar 100 and the sheet metal member 110 can be improved. Further, when the sheet metal bus bar 100 and the sheet metal member 110 are integrally molded by the resin member 120, a stepped pin is inserted into the through hole 117 and the sheet metal bus bar 100 is pressed at the stepped portion, whereby the position accuracy of the sheet metal bus bar 100 in the horizontal direction is accurate. , And the position accuracy in the vertical direction can be improved. Further, when the through hole 117 is provided only in the sheet metal member 110 and one side of the sheet metal bus bar 100 is pressed with a pin, the distance between the sheet metal bus bar 100 and the sheet metal member 110 can be kept constant.

導体部１０２ａの貫通孔１１７の内径は板金部材１１０ｂの貫通孔１１７の内径よりも小さい。板金バスバー１００に設ける貫通孔１１７を小径にすることで、大電流が流れる板金バスバー１００の断面積の縮小を抑制することができる。また、板金バスバー１００の断面積の縮小が抑制されるので、板金バスバー１００の発熱を抑制することができる。 The inner diameter of the through hole 117 of the conductor portion 102a is smaller than the inner diameter of the through hole 117 of the sheet metal member 110b. By reducing the diameter of the through hole 117 provided in the sheet metal bus bar 100, it is possible to suppress a reduction in the cross-sectional area of the sheet metal bus bar 100 through which a large current flows. Further, since the reduction of the cross-sectional area of the sheet metal bus bar 100 is suppressed, the heat generation of the sheet metal bus bar 100 can be suppressed.

以上のように、実施の形態１によるバスバーモジュール２０において、板金バスバー１００の導体部１０２と対向した板状部１１１の他方の面が樹脂部材１２０から外部に露出すると共に、板金バスバー１００と板金部材１１０とは樹脂部材１２０で一体化されているため、板金バスバー１００で発生した熱は効率良く板金部材１１０を介して放熱されるので、板金バスバー１００の温度上昇を抑制しつつ、バスバーモジュール２０を小型化することができる。板金バスバー１００の接続端部１０１を樹脂部材１２０から外部に露出させた場合、接続端部１０１とパワー系主回路部品または回路基板１５とを容易に接続することができる。接続端部１０１が導体部１０２に対して直角に折り曲げられている場合、バスバーモジュール２０を小型化することができ、バスバーモジュール２０と対向して設けられるパワー系主回路部品または回路基板１５と接続端部１０１とを容易に接続することができる。接続端部１０１と導体部１０２との間の折り曲げ箇所に隣接した導体部１０２の部分が樹脂部材１２０から外部に露出している場合、板金バスバー１００を樹脂部材１２０でインサート成形する際、成形金型で板金バスバー１００の接続端部１０１と隣接した導体部１０２の部分の双方を確実に保持することができる。また、双方を確実に保持できるため、接続端部１０１の成形精度を向上させることができる。 As described above, in the bus bar module 20 according to the first embodiment, the other surface of the plate-shaped portion 111 facing the conductor portion 102 of the sheet metal bus bar 100 is exposed to the outside from the resin member 120, and the sheet metal bus bar 100 and the sheet metal member are exposed to the outside. Since the 110 is integrated with the resin member 120, the heat generated by the sheet metal bus bar 100 is efficiently dissipated through the sheet metal member 110, so that the bus bar module 20 can be moved while suppressing the temperature rise of the sheet metal bus bar 100. It can be miniaturized. When the connection end 101 of the sheet metal bus bar 100 is exposed to the outside from the resin member 120, the connection end 101 can be easily connected to the power system main circuit component or the circuit board 15. When the connection end 101 is bent at a right angle to the conductor 102, the bus bar module 20 can be miniaturized and connected to a power system main circuit component or a circuit board 15 provided opposite to the bus bar module 20. The end 101 can be easily connected. When the portion of the conductor portion 102 adjacent to the bent portion between the connection end portion 101 and the conductor portion 102 is exposed to the outside from the resin member 120, when the sheet metal bus bar 100 is insert-molded by the resin member 120, the molding die Both the connection end 101 of the sheet metal bus bar 100 and the adjacent conductor 102 can be reliably held by the mold. Further, since both can be reliably held, the molding accuracy of the connection end portion 101 can be improved.

また、接続端部１０１の幅が接続端部１０１の終端の方向に縮小されている場合、接続端部１０１と接続する回路基板１５のスルーホールの穴径を小型にすることができる。また、接続端部１０１の熱容量が小さくなるので接続端部１０１と回路基板１５のランドとを接続する半田が溶融しやすくなるため、接続端部１０１の半田付け性を向上させることができる。また、導体部１０２に折り曲げられて段差が形成された段差部１０３を設けている場合、接続端部１０１の高さを容易に変えることができる。 Further, when the width of the connection end portion 101 is reduced in the direction of the end of the connection end portion 101, the hole diameter of the through hole of the circuit board 15 connected to the connection end portion 101 can be reduced. Further, since the heat capacity of the connection end 101 is reduced, the solder connecting the connection end 101 and the land of the circuit board 15 is easily melted, so that the solderability of the connection end 101 can be improved. Further, when the conductor portion 102 is provided with the step portion 103 which is bent to form a step, the height of the connection end portion 101 can be easily changed.

また、板金バスバー１００の導体部１０２及び板金部材１１０に貫通孔１１７を設けている場合、バスバーモジュール２０を樹脂部材１２０で封止する際、樹脂部材１２０が回り込みにくい板金バスバー１００と板金部材１１０との間にも樹脂部材１２０が充填されやすくなる。導体部１０２及び板金部材１１０はそれぞれ２つの貫通孔１１７を備え、導体部１０２の貫通孔１１７と板金部材１１０の貫通孔１１７とは導体部１０２の表面に直交する方向に見て重なる位置に設けられている場合、板金バスバー１００と板金部材１１０を樹脂部材１２０で一体成形する際に双方の貫通孔１１７にピンを挿入することで、板金バスバー１００と板金部材１１０の回り止めができ、板金バスバー１００と板金部材１１０の水平方向の位置精度を向上することができる。また、板金バスバー１００の水平方向の位置精度が向上するため、板金バスバー１００と接続される箇所と板金バスバー１００との接続の信頼性を向上させることができる。また、導体部１０２の貫通孔１１７の内径が板金部材１１０の貫通孔１１７の内径よりも小さい場合、大電流が流れる板金バスバー１００の断面積の縮小を抑制することができる。 Further, when the conductor portion 102 of the sheet metal bus bar 100 and the sheet metal member 110 are provided with through holes 117, when the bus bar module 20 is sealed with the resin member 120, the sheet metal bus bar 100 and the sheet metal member 110 are difficult to wrap around. The resin member 120 is easily filled between the spaces. The conductor portion 102 and the sheet metal member 110 each have two through holes 117, and the through holes 117 of the conductor portion 102 and the through holes 117 of the sheet metal member 110 are provided at positions where they overlap when viewed in a direction orthogonal to the surface of the conductor portion 102. If the sheet metal bus bar 100 and the sheet metal member 110 are integrally molded with the resin member 120, the sheet metal bus bar 100 and the sheet metal member 110 can be prevented from rotating by inserting a pin into both through holes 117. The horizontal positional accuracy of the 100 and the sheet metal member 110 can be improved. Further, since the position accuracy of the sheet metal bus bar 100 in the horizontal direction is improved, the reliability of the connection between the portion connected to the sheet metal bus bar 100 and the sheet metal bus bar 100 can be improved. Further, when the inner diameter of the through hole 117 of the conductor portion 102 is smaller than the inner diameter of the through hole 117 of the sheet metal member 110, it is possible to suppress the reduction of the cross-sectional area of the sheet metal bus bar 100 through which a large current flows.

また、複数の板金バスバー１００のそれぞれが備えた導体部１０２が同一平面に設けられた場合、バスバーモジュール２０の厚みの均一化が図られ、バスバーモジュール２０を薄型化することができる。また、導体部１０２と板金部材１１０との距離が均一化されるので、板金部材１１０を介した放熱の経路の均一化を図ることができる。複数の板金バスバー１００は樹脂部材１２０を介して積層されている場合、樹脂部材１２０を介して積層させることで、積層した板金バスバー１００と板金バスバー１００との間の絶縁を容易に確保することができる。また、バスバーモジュール２０の厚みを大きくすることなく絶縁を容易に確保することができる Further, when the conductor portions 102 provided in each of the plurality of sheet metal bus bars 100 are provided on the same plane, the thickness of the bus bar module 20 can be made uniform, and the bus bar module 20 can be made thinner. Further, since the distance between the conductor portion 102 and the sheet metal member 110 is made uniform, it is possible to make the heat radiation path through the sheet metal member 110 uniform. When the plurality of sheet metal bus bars 100 are laminated via the resin member 120, the insulation between the laminated sheet metal bus bar 100 and the sheet metal bus bar 100 can be easily ensured by laminating via the resin member 120. can. In addition, insulation can be easily secured without increasing the thickness of the bus bar module 20.

また、実施の形態１による電力変換装置１において、板金部材１１０の板状部１１１の他方の面が樹脂部材１２０から外部に露出すると共に、板金バスバー１００と板金部材１１０とは樹脂部材１２０で一体化されているバスバーモジュール２０を備えており、高電圧及び大電流の伝送を回路基板１５のパターンだけで行わないため、電力変換装置１を小型化することができる。また、パワー系主回路部品と回路基板１５との間にバスバーモジュール２０が配置されている場合、配置面８ｃに配置されたパワー系主回路部品の配置面８ｃからの突出高さの高低差を吸収することができ、パワー系主回路部品と回路基板１５との間の絶縁距離を短縮することができる。また、バスバーモジュール２０が備えた板金部材１１０が回路基板１５の側に配置されている場合、回路基板１５及び回路基板１５に実装された制御系の回路部品が板金バスバー１００で発生した熱で煽られることがなく、電力変換装置１は安定して動作することができる。また、接続端部１０１とパワー系主回路部品との接続部が樹脂カバー１６で覆われている場合、接続部と回路基板１５との間の絶縁を確保しつつ、接続部と回路基板１５との距離を短縮することができる。 Further, in the power conversion device 1 according to the first embodiment, the other surface of the plate-shaped portion 111 of the sheet metal member 110 is exposed to the outside from the resin member 120, and the sheet metal bus bar 100 and the sheet metal member 110 are integrated by the resin member 120. Since the bus bar module 20 is provided and the high voltage and the large current are not transmitted only by the pattern of the circuit board 15, the power conversion device 1 can be miniaturized. Further, when the bus bar module 20 is arranged between the power system main circuit component and the circuit board 15, the height difference of the protrusion height from the arrangement surface 8c of the power system main circuit component arranged on the arrangement surface 8c is increased. It can be absorbed and the insulation distance between the power system main circuit component and the circuit board 15 can be shortened. Further, when the sheet metal member 110 provided in the bus bar module 20 is arranged on the side of the circuit board 15, the circuit board 15 and the circuit components of the control system mounted on the circuit board 15 are heated by the heat generated by the sheet metal bus bar 100. The power conversion device 1 can operate stably without being affected. Further, when the connection portion between the connection end portion 101 and the power system main circuit component is covered with the resin cover 16, the connection portion and the circuit board 15 are connected while ensuring insulation between the connection portion and the circuit board 15. The distance can be shortened.

また、回路基板１５が備えたスルーホールを介して接続端部１０１と回路基板１５とが接続されている場合、バスバー同士をネジで締結する構造もしくはラグ端子を基板に実装してラグ端子を介して接合する構造に比べて、実装面積を削減することができる。また、樹脂部材１２０から露出している板金部材１１０の一部分である冷却部１１２と冷却器８とが接している場合、板金バスバー１００で発生した熱を冷却器８に板金部材１１０を介して放熱することができる。また、冷却器８が直方体状の冷却器８の本体部８ａの外周に沿って本体部８ａの一方の面から立設した外周壁８ｂを有し、外周壁８ｂと冷却部１１２とが接している場合、外周壁８ｂと冷却部１１２とは隣接しているため容易に冷却器８に放熱することができる。また、冷却器８の他方の面に冷媒１１が流れる冷却水路８ｄが形成され、冷却水路８ｄはカバーで覆われている場合、冷却器８の配置面８ｃに実装されたパワー系主回路部品の発熱を抑制することができる。また、冷却器８の本体部８ａの他方の面の側に冷却水路８ｄを設けることで、冷却面となる配置面８ｃを広範囲に確保できるため、配置面８ｃに実装されたパワー系主回路部品の放熱面積を十分確保できるとともに、パワー系主回路部品の配置の自由度を向上させることができる。また、冷却器８の配置面８ｃに複数のパワー系主回路部品のそれぞれが配置される凹部が形成されている場合、パワー系主回路部品が配置面８ｃ上に容易に位置決めされて配置されるため、電力変換装置１の生産性を向上することができる。 Further, when the connection end 101 and the circuit board 15 are connected via a through hole provided in the circuit board 15, a structure in which the bus bars are fastened with screws or a lug terminal is mounted on the board and the lug terminal is used. The mounting area can be reduced as compared with the structure in which the joints are joined. Further, when the cooling unit 112, which is a part of the sheet metal member 110 exposed from the resin member 120, and the cooler 8 are in contact with each other, the heat generated by the sheet metal bus bar 100 is dissipated to the cooler 8 via the sheet metal member 110. can do. Further, the cooler 8 has an outer peripheral wall 8b erected from one surface of the main body 8a along the outer periphery of the main body 8a of the rectangular parallelepiped cooler 8, and the outer peripheral wall 8b and the cooling portion 112 are in contact with each other. If so, the outer peripheral wall 8b and the cooling unit 112 are adjacent to each other, so that heat can be easily dissipated to the cooler 8. Further, when a cooling water channel 8d through which the refrigerant 11 flows is formed on the other surface of the cooler 8 and the cooling water channel 8d is covered with a cover, the power system main circuit component mounted on the arrangement surface 8c of the cooler 8 Fever can be suppressed. Further, by providing the cooling water channel 8d on the side of the other surface of the main body 8a of the cooler 8, the arrangement surface 8c serving as the cooling surface can be secured in a wide range, so that the power system main circuit component mounted on the arrangement surface 8c can be secured. It is possible to secure a sufficient heat dissipation area and improve the degree of freedom in arranging the power system main circuit components. Further, when the arrangement surface 8c of the cooler 8 is formed with a recess in which each of the plurality of power system main circuit components is arranged, the power system main circuit component is easily positioned and arranged on the arrangement surface 8c. Therefore, the productivity of the power conversion device 1 can be improved.

実施の形態２．
実施の形態２に係る電力変換装置１について説明する。図１１は、実施の形態２に係る電力変換装置１の断面図、図１２は図１１の一部を拡大して示した電力変換装置１の要部断面図である。実施の形態２に係る電力変換装置１は、冷却器８が内側壁８ｇを備えた構成になっている。 Embodiment 2.
The power conversion device 1 according to the second embodiment will be described. FIG. 11 is a cross-sectional view of the power conversion device 1 according to the second embodiment, and FIG. 12 is a cross-sectional view of a main part of the power conversion device 1 in which a part of FIG. 11 is enlarged. The power conversion device 1 according to the second embodiment has a configuration in which the cooler 8 includes an inner side wall 8 g.

図１１は、図３のＣ−Ｃ断面位置で切断した電力変換装置１の断面図である。冷却器８は、外周壁８ｂの内側において、パワー系主回路部品であるトランス２０１と整流回路部２０２との間に本体部８ａの配置面８ｃから立設すると共に外周壁８ｂにつながった内側壁８ｇを有する。内側壁８ｇと外周壁８ｂとで取り囲まれたトランス２０１は放熱樹脂２０１ｃで封止されている。なお、ここではトランス２０１と整流回路部２０２との間に設けた内側壁８ｇを示しているが、他のパワー系主回路部品との間に内側壁８ｇを設けて他のパワー系主回路部品を放熱樹脂２０１ｃで封止しても構わない。 FIG. 11 is a cross-sectional view of the power conversion device 1 cut at the CC cross-sectional position of FIG. The cooler 8 stands inside the outer peripheral wall 8b from the arrangement surface 8c of the main body 8a between the transformer 201 and the rectifier circuit portion 202, which are the main circuit components of the power system, and the inner side wall connected to the outer peripheral wall 8b. It has 8 g. The transformer 201 surrounded by the inner side wall 8g and the outer peripheral wall 8b is sealed with the heat radiating resin 201c. Although the inner side wall 8 g provided between the transformer 201 and the rectifier circuit unit 202 is shown here, the inner side wall 8 g is provided between the transformer 201 and the rectifier circuit unit 202 to provide another power system main circuit component. May be sealed with the heat radiating resin 201c.

以上のように、実施の形態２による電力変換装置１において、冷却器８はパワー系主回路部品の間に本体部８ａの配置面８ｃから立設すると共に外周壁８ｂにつながった内側壁８ｇを有し、内側壁８ｇと外周壁８ｂとで取り囲まれたトランス２０１は放熱樹脂２０１ｃで封止されているため、トランス２０１の放熱効果を更に向上させることができる。 As described above, in the power conversion device 1 according to the second embodiment, the cooler 8 stands between the main circuit components of the power system from the arrangement surface 8c of the main body 8a and has an inner side wall 8g connected to the outer peripheral wall 8b. Since the transformer 201 having the inner side wall 8g and surrounded by the outer peripheral wall 8b is sealed with the heat radiating resin 201c, the heat radiating effect of the transformer 201 can be further improved.

また本願は、様々な例示的な実施の形態及び実施例が記載されているが、１つ、または複数の実施の形態に記載された様々な特徴、態様、及び機能は特定の実施の形態の適用に限られるのではなく、単独で、または様々な組み合わせで実施の形態に適用可能である。
従って、例示されていない無数の変形例が、本願明細書に開示される技術の範囲内において想定される。例えば、少なくとも１つの構成要素を変形する場合、追加する場合または省略する場合、さらには、少なくとも１つの構成要素を抽出し、他の実施の形態の構成要素と組み合わせる場合が含まれるものとする。 The present application also describes various exemplary embodiments and examples, although the various features, embodiments, and functions described in one or more embodiments are those of a particular embodiment. It is not limited to application, but can be applied to embodiments alone or in various combinations.
Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed herein. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

１電力変換装置、２交流電源、３負荷、４パワー系主回路部、４ａＤＣ／ＤＣコンバータ部、５制御回路部、６入力フィルタ回路部、７出力フィルタ回路部、８冷却器、８ａ本体部、８ｂ外周壁、８ｃ配置面、８ｄ冷却水路、８ｅ位置決め穴、８ｆ接触部、８ｇ内側壁、９カバー、１０水路カバー、１１冷媒、１５回路基板、１５ａスルーホール、１５ｂスルーホール、１６樹脂カバー、２０バスバーモジュール、２０ａ位置決めピン、１００板金バスバー、１０１接続端部、１０２導体部、１０３段差部、１１０板金部材、１１１板状部、１１２冷却部、１１５ナット、１１６ブッシュ、１１７貫通孔、１２０樹脂部材、２０１トランス、２０１ａ１次側コイル、２０１ｂ２次側コイル、２０１ｃ放熱樹脂、２０２整流回路部、２０２ａダイオード、２０３平滑回路部、２０３ａ平滑リアクトル、２０４ＰＦＣリアクトル、２０５パワー線、２０６入力線、２０７出力線 1 Power converter, 2 AC power supply, 3 load, 4 power system main circuit, 4a DC / DC converter, 5 control circuit, 6 input filter circuit, 7 output filter circuit, 8 cooler, 8a main body , 8b outer wall, 8c placement surface, 8d cooling water channel, 8e positioning hole, 8f contact part, 8g inner side wall, 9 cover, 10 water channel cover, 11 refrigerant, 15 circuit board, 15a through hole, 15b through hole, 16 resin cover , 20 bus bar module, 20a positioning pin, 100 sheet metal bus bar, 101 connection end, 102 conductor part, 103 step part, 110 sheet metal member, 111 plate-shaped part, 112 cooling part, 115 nut, 116 bush, 117 through hole, 120 Resin member, 201 transformer, 201a primary side coil, 201b secondary side coil, 201c heat dissipation resin, 202 rectifying circuit part, 202a diode, 203 smoothing circuit part, 203a smoothing reactor, 204 PFC reactor, 205 power line, 206 input line , 207 Output line

Claims

A sheet metal bus bar having a plurality of plate-shaped connection ends connected to components constituting an electric circuit, and a plate-shaped conductor portion connecting between the plurality of connection ends.
A sheet metal member having a plate-shaped portion whose one surface faces the conductor portion,
A sheet metal bus bar and a resin member surrounding each of the sheet metal members are provided.
A bus bar module in which the other surface of the plate-shaped portion is exposed to the outside from the resin member, and the sheet metal bus bar and the sheet metal member are integrated with the resin member.

The bus bar module according to claim 1, wherein the connection end is exposed to the outside from the resin member.

The bus bar module according to claim 2, wherein the connecting end portion is bent at a right angle to the conductor portion.

The bus bar module according to claim 3, wherein the portion of the conductor portion adjacent to the bent portion between the connection end portion and the conductor portion is exposed to the outside from the resin member.

The bus bar module according to claim 2, wherein the width of the connection end is reduced in the direction of the end of the connection end.

The bus bar module according to claim 2, wherein the conductor portion is provided with a step portion formed by bending to form a step portion.

The bus bar module according to claim 1, wherein the conductor portion and the sheet metal member of the sheet metal bus bar are provided with through holes.

The conductor portion and the sheet metal member each have two through holes.
The through hole of the conductor portion and the through hole of the sheet metal member are provided at positions where they overlap each other when viewed in a direction orthogonal to the surface of the conductor portion.
The bus bar module according to claim 7, wherein the inner diameter of the through hole of the conductor portion is smaller than the inner diameter of the through hole of the sheet metal member.

Equipped with multiple sheet metal busbars
The bus bar module according to claim 1, wherein the conductor portion provided in each of the plurality of sheet metal bus bars is provided on the same plane.

Equipped with multiple sheet metal busbars
The bus bar module according to claim 1, wherein the plurality of sheet metal bus bars are laminated via the resin member.

With multiple electrical components
A cooler in which a plurality of the electric components are arranged side by side on one surface, and
The bus bar module according to any one of claims 1 to 10, which is arranged so as to face one surface of the cooler.
A circuit board on which a plurality of circuit components are mounted, which is arranged so as to face one surface of the cooler, is provided.
The plurality of the electric components are connected to the plurality of connection ends or the circuit boards provided by the bus bar module, and the plurality of the connection ends provided by the bus bar module are the plurality of the electric components or the circuit boards. The circuit board is a power conversion device connected to a plurality of the connection ends or the electric components included in the bus bar module.

The power conversion device according to claim 11, wherein the bus bar module is arranged between the electric component and the circuit board.

The power conversion device according to claim 12, wherein the sheet metal member provided in the bus bar module is arranged on the side of the circuit board.

The power conversion device according to claim 11, wherein the connection portion between the connection end portion and the electric component is covered with a resin cover.

The power conversion device according to claim 11, wherein the connection end portion and the circuit board are connected to each other through a through hole provided in the circuit board.

The power conversion device according to claim 11, wherein a cooling unit that is a part of the sheet metal member exposed from the resin member and the cooler are in contact with each other.

The claim that the cooler has an outer peripheral wall erected from one surface of the main body along the outer periphery of the main body of the rectangular parallelepiped cooler, and the outer peripheral wall and the cooling portion are in contact with each other. 16. The power conversion device according to 16.

The cooler has an inner side wall that is erected from one surface of the main body and is connected to the outer peripheral wall between each of the plurality of electric parts inside the outer peripheral wall, and has an inner side wall that is connected to the outer peripheral wall. The power conversion device according to claim 17, wherein the electric component surrounded by the outer peripheral wall is sealed with a resin.

The power conversion device according to any one of claims 11 to 18, wherein a water channel through which a refrigerant flows is formed on the other surface of the cooler, and the water channel is covered with a cover.

The power conversion device according to any one of claims 11 to 19, wherein a recess in which each of the plurality of electric components is arranged is formed on one surface of the cooler.

Along one surface of the cooler, the transformer, the rectifier circuit unit, and the smoothing reactor, which are the electric components, are provided side by side from one side to the other side in the arrangement direction.
The rectifier circuit unit has a height protruding from one surface of the cooler lower than that of the transformer and the smoothing reactor.
In the transformer, the rectifier circuit unit, and the bus bar module provided so as to face the smoothing reactor, the portion facing the rectifier circuit unit faces the transformer and the smoothing reactor. The power conversion device according to claim 12, wherein steps are formed on both side portions of the rectifier circuit unit in the arrangement direction so as to be closer to one surface of the cooler than the portion.