KR102528422B1 - Power converter - Google Patents

Abstract

The present invention relates to a power converter capable of reducing the cost and number of parts for manufacturing the power converter and simplifying the process, comprising: an input wire receiving a high voltage from a power board; an output bus bar in which the input wire is accommodated and induced electromotive force is generated by an electromagnetic induction action with the input wire; A core surrounding the input wire and the output bus bar; including, but cured in a state injected between the input wire, the output bus bar, and the core to insulate the input wire, the output bus bar, and the core from each other It further includes; a bobbin made of a potting liquid.

Description

Power converter {POWER CONVERTER}

The present invention relates to a power conversion device, and more particularly, to a power conversion device capable of reducing the cost and number of parts for manufacturing the power conversion device and simplifying the process.

In general, high voltage and current are required to drive a motor in an electric vehicle driven only by a motor and a hybrid vehicle driven by an engine and a motor.

Therefore, there is a need for a hybrid power control unit (HPCU) that interconnects an engine, a motor, and a battery according to driving conditions.

HPCU consists of power supply products such as LDC (Low Voltage DC-DC Converter), Inverter, and HCU (Hybrid Control Unit).

The double LDC is composed of a power unit for changing a high voltage input to a low voltage input and a control unit for controlling the power unit.

And, the power unit is largely composed of an input power board, a transformer, an output inductor, an output power board, and the like.

On the other hand, the transformer and the output inductor serve to change high voltage power to low voltage, and are essential in power conversion devices.

In the case of these transformers and output inductors, they are largely composed of a core, a bus bar, and a bobbin.

The bus bar serves as a passage for current, the bobbin serves as insulation and fixation, and the core plays a role of being magnetic.

When a current flows in the primary side, a magnetic field is formed according to the flowing current, and the generated magnetic field induces an induced current to flow in the secondary side that is insulated from the primary side, thereby converting power on the principle of obtaining a desired voltage.

Parts using magnetism, such as transformers and inductors, are called magnetic materials.

The magnetic material uses a bobbin made of plastic to insulate or fix between the core and the bus bar or between the bus bars.

These bobbins are usually made of plastic materials.

Thus, bobbins are manufactured through injection molding.

These magnetic bodies are assembled with bobbins, cores, and bus bars manufactured through injection to form a magnetic body assembly.

Therefore, in order to make one magnetic body, each mold is required for each bobbin for injection.

As a result, the number of molds for manufacturing the bobbin increases, and there is a problem in that cost increases.

In addition, if the shape of the bobbin is modified even a little, the mold for injection must also be modified to correspond with the modified bobbin.

Due to this, it takes a lot of cost and time to manufacture the magnetic body assembly.

In addition, since magnetic materials are manually assembled one by one, the number of bobbins reduces workability and eventually productivity.

An object of the present invention has been proposed in view of the above situation, and a bobbin for mutually insulating a core and a bus bar is formed of silicon for a vehicle that can reduce the cost and number of parts and simplify the process for manufacturing a control device for a vehicle. A power control device is provided.

A power conversion device according to an embodiment of the present invention includes an input wire receiving a high voltage from a power board; an output bus bar in which the input wire is accommodated and induced electromotive force is generated by an electromagnetic induction action with the input wire; A core surrounding the input wire and the output bus bar; including, but cured in a state injected between the input wire, the output bus bar, and the core to insulate the input wire, the output bus bar, and the core from each other It further includes; a bobbin made of a potting liquid.

The potting liquid is silicone that is hardened while injected into the input wire, the output bus bar, and the core so as to mutually insulate the input wire, the output bus bar, and the core.

The core may include an upper core disposed above the output bus bar and generating magnetic flux when a high voltage is applied from the power board; A lower core disposed below the output bus bar in a structure symmetrical to the upper core with respect to the output bus bar, wherein a first coupling protrusion protrudes from the lower surface of the upper core, and a first coupling protrusion protrudes from the lower surface of the upper core, and 2 engaging protrusions protrude, the input wire is wound around the first engaging protrusion and the second engaging protrusion, and an insertion hole into which the lower end of the first engaging protrusion and the upper end of the second engaging protrusion are inserted is formed , A through hole through which the first coupling protrusion and the second coupling protrusion pass is formed in the output bus bar.

The first coupling protrusion and the second coupling protrusion are spaced apart from each other, and a bobbin made of the potting liquid is injected between the first coupling protrusion and the second coupling protrusion and then cured to form the first coupling protrusion and the second coupling protrusion. are insulated from each other.

The power conversion device according to the present invention can simplify the process and improve workability and productivity by injecting a liquid silicone potting liquid into the empty space of the input wire, output bus bar, and core and then hardening it to form a bobbin. There are effects that can be improved.

In addition, there is an effect of reducing costs because a mold for newly fabricating a bobbin is not manufactured again due to a change in the position between the input wire, the output bus bar, and the core or a change in the internal shape.

A bobbin is disposed between the lower end of the first engaging protrusion and the upper end of the second engaging protrusion, thereby preventing the lower end of the first engaging protrusion and the upper end of the second engaging protrusion from contacting each other and being damaged due to vibration caused by an external force. It works.

1 is a perspective view showing a power conversion device according to an embodiment of the present invention;
2 is an exploded perspective view in which the power converter shown in FIG. 1 is disassembled;
3 is a cross-sectional view taken along line A-A′ shown in FIG. 1;
4 is a flow chart showing a coupling sequence of a power converter according to an embodiment of the present invention;

Advantages and features of the present invention, and methods of achieving them, will become clear with reference to the detailed description of the following embodiments taken in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in various different forms, only these embodiments make the disclosure of the present invention complete, and common knowledge in the art to which the present invention belongs. It is provided to fully inform the holder of the scope of the invention, and the present invention is defined by the description of the claims. Meanwhile, terms used in this specification are for describing the embodiments and are not intended to limit the present invention. In this specification, singular forms also include plural forms unless specifically stated otherwise in a phrase. As used herein, "comprises" or "comprising" means the presence or absence of one or more other elements, steps, operations and/or elements other than the recited elements, steps, operations and/or elements; do not rule out additions.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a perspective view showing a power converter according to an embodiment of the present invention, FIG. 2 is an exploded perspective view of the power converter shown in FIG. 1, and FIG. 3 is an A-A′ shown in FIG. This is a cut section.

1 to 3, the power converter according to the present embodiment includes an input wire 100, an output bus bar 200, a core 300, and a bobbin 400.

The input wire 100 receives a high voltage from the power board.

The input wire 100 is made of a conductor through which current flows, receives a high voltage from the power board, and transfers power generated by electromagnetic induction to the output bus bar 200.

An insertion groove 110 into which the core 300 is inserted is formed in the input wire 100 .

The input wire 100 is accommodated in the output bus bar 200, and induced electromotive force is generated by electromagnetic induction with the input wire 100.

More specifically, in the output bus bar 200, when a high voltage is applied to the input wire 100 through the power board, current flows through the input wire 100 and magnetic flux is generated inside the core 300.

In addition, the magnetic flux generates induced electromotive force while passing through the output bus bar 200, and the generated energy is transferred to the outside through this principle.

The output bus bar 200 includes a first bus bar 210, a second bus bar 220, a connecting portion 230, and a through hole 240.

The first bus bar 210 is disposed between the upper portion of the input wire 100 and the core 300, and the second bus bar 220 is disposed between the lower portion of the input wire 100 and the core 300.

The connection part 230 connects the first bus bar 210 and the second bus bar 220 to each other.

The through hole 240 couples the core 300 to the output bus bar 200 .

The core 300 surrounds the input wire and the output bus bar 200 .

The core 300 includes an upper core 310 and a lower core 320 .

The upper core 310 is disposed above the output bus bar 200, and magnetic flux is generated when a high voltage is applied from the power board.

Further, the first coupling protrusion 311 protrudes downward from the lower surface of the upper core 310 .

The lower core 320 is disposed below the output bus bar 200 in a structure symmetrical to the upper core 310 with respect to the output bus bar 200 .

And, the second coupling protrusion 321 protrudes upward from the upper surface of the lower core 320 .

Meanwhile, the input wire 100 is wound around the first coupling protrusion 311 of the upper core 310 and the second coupling protrusion 321 of the lower core 320 .

Due to this, an insertion groove 110 is formed in the input wire 100 by the first coupling protrusion 311 and the second coupling protrusion 321 so that the lower end of the first coupling protrusion 311 is inserted downward, The upper end of the second coupling protrusion 321 is inserted upward.

In addition, the first coupling protrusion 311 passes through the through hole 240 of the output bus bar 200 in a downward direction, and the second coupling protrusion 321 penetrates in an upward direction.

Therefore, the first coupling protrusion 311 of the upper core 310 and the second coupling protrusion 321 of the lower core 320 pass through the insertion groove 110 of the input wire 100 and the output bus bar 200. By inserting and penetrating the ball 240, the upper core 310 and the lower core 320 can protect the input wire 100 and the output bus bar 200 from impact or foreign matter outside the power converter, and The movement of the wire 100 and the output bus bar 200 can be restricted.

In addition, when current flows to the output bus bar 200 through the input wire 100 to which a high voltage is applied from the power board, magnetic flux is generated inside the upper core 310 and the lower core 320 and Induction electromotive force can be better generated in the output bus bar 200 by electromagnetic induction.

On the other hand, when the output bus bar 200 and the input wire 100 come into contact with each other, a short circuit occurs, which causes a failure of the power conversion device.

To prevent this, a bobbin 400 is formed between the input wire 100, the output bus bar 200, and the core 300.

The bobbin 400 is hardened in a state of being injected between the input wire 100, the output bus bar 200, and the core 300 to insulate the input wire 100, the output bus bar 200, and the core 300 from each other. let it

To this end, the bobbin 400 is formed of a potting liquid made of silicon.

Therefore, between the upper core 310 of the plurality of bobbins 400 and the first bus bar, between the first bus bar 210 and the input wire 100, between the input wire 100 and the second bus bar 220, Unlike the prior art, which was disposed between the second bus bar 220 and the lower core 320, in the bobbin 400 according to an embodiment of the present invention, a potting liquid made of silicon is applied to the core 300 and the output bus bar ( 200) and the input wire 100 are insulated from each other, and hardened while being injected into the empty space of the input wire 100, the output bus bar 200, and the core 300.

That is, by filling the empty spaces of the input wire 100, the output bus bar 200, and the core 300 with a flexible silicon material, it is different from the prior art in which a plurality of bobbins 400 were manually assembled one by one. Otherwise, the bobbin 400 of the present invention can simplify the process and improve workability and productivity.

In addition, due to a change in the position between the input wire 100, the output bus bar 200, and the core 300 or a change in the internal shape, the mold is not modified to newly manufacture the bobbin 400, which can reduce costs. there is.

Meanwhile, the first coupling protrusion 311 and the second coupling protrusion 321 are spaced apart from each other.

For this reason, the bobbin 400 made of potting liquid is injected between the lower end of the first engaging protrusion 311 and the upper end of the second engaging protrusion 321, and then cured to form the first engaging protrusion 311 and the second engaging protrusion 321. (321) are insulated from each other.

In addition, since the bobbin 400 is disposed between the lower end of the first engaging protrusion 311 and the upper end of the second engaging protrusion 321, the lower end of the first engaging protrusion 311 and the second coupling due to vibration caused by an external force. It is possible to prevent the upper ends of the protrusions 321 from being damaged due to contact with each other.

Hereinafter, a preferred embodiment of a coupling sequence of a power converter according to an embodiment of the present invention will be described in detail with reference to FIG. 4 .

4 is a flowchart illustrating a coupling sequence of a power converter according to an embodiment of the present invention.

As shown in FIG. 4 , according to the assembly sequence of the power converter according to the embodiment of the present invention, the second bus bar 220 is stacked on the upper surface of the lower core 320 (S410).

Then, the input wire 100 is stacked on the upper surface of the second bus bar 220 (S420).

Subsequently, the first bus bar 210 is stacked on the upper surface of the input wire 100 (S430).

Then, the upper core 310 is stacked on the upper surface of the first bus bar 210 (S440).

Subsequently, the first bus bar 210 and the second bus bar 220 are connected via a connection unit (S450).

In addition, a potting liquid made of silicon is injected between the core 300, the input wire 100, and the output bus bar 200, and then cured to form the bobbin 400 (S460).

That is, by filling the empty spaces of the input wire 100, the output bus bar 200, and the core 300 with a flexible silicon material, the process can be simplified and workability and productivity can be improved.

As described above, the power conversion device according to the present invention injects a potting liquid of a flexible silicone material into the empty space of the input wire 100, the output bus bar 200, and the core 300, and then cures the bobbin 400 ), the process can be simplified, and workability and productivity can be improved.

In addition, due to a change in the position between the input wire 100, the output bus bar 200, and the core 300 or a change in the internal shape, it is not necessary to manufacture a new mold for the bobbin 400, thereby reducing cost. can do.

Since the bobbin 400 is disposed between the lower end of the first engaging protrusion 311 and the upper end of the second engaging protrusion 321, the lower end of the first engaging protrusion 311 and the second engaging protrusion ( 321) can be prevented from being damaged due to contact with each other.

The present invention is not limited to the above-described embodiments, and can be implemented with various modifications within the scope of the technical idea of the present invention.

100: input wire 110: insertion groove
200: output bus bar 210: first bus bar
220: second bus bar 230: connection
240: through hole 300: core
310: upper core 311: first coupling protrusion
320: lower core 321: second coupling protrusion
400: bobbin

Claims (4)

An input wire receiving a high voltage from the power board;
an output bus bar in which the input wire is accommodated and induced electromotive force is generated by an electromagnetic induction action with the input wire;
A core surrounding the input wire and the output bus bar;
A bobbin made of a potting liquid that is hardened in a state injected between the input wire, the output bus bar, and the core to insulate the input wire, the output bus bar, and the core from each other; further comprising,
the core,
an upper core disposed above the output bus bar and generating magnetic flux when a high voltage is applied from the power board;
A lower core disposed under the output bus bar in a structure symmetrical to the upper core with respect to the output bus bar;
A first coupling protrusion protrudes from the lower surface of the upper core,
A second coupling protrusion protrudes from the upper surface of the lower core,
The first coupling protrusion and the second coupling protrusion are spaced apart from each other,
A bobbin made of the potting liquid is injected between the first coupling protrusion and the second coupling protrusion and then cured so that the first coupling protrusion and the second coupling protrusion are insulated from each other.
phosphorus power converter.
The method of claim 1, wherein the potting liquid,
Silicone hardened while being injected into the input wire, the output bus bar, and the core so as to mutually insulate the input wire, the output bus bar, and the core.
phosphorus power converter.
The method of claim 1, wherein the core,
The input wire is wound around the first coupling protrusion and the second coupling protrusion, and an insertion hole into which the lower end of the first coupling protrusion and the upper end of the second coupling protrusion are inserted is formed,
A through hole through which the first coupling protrusion and the second coupling protrusion pass is formed in the output bus bar.
phosphorus power converter.
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