阅读说明：本技术 电力转换装置 (Power conversion device ) 是由 瓜生勇太 于 2020-11-06 设计创作，主要内容包括：一种电力转换装置,能确保散热性并实现装置的小型轻量化、低成本化。电磁感应设备(1)包括：磁性芯体(4),所述磁性芯体构成闭合磁路；以及线圈体(3),所述线圈体由板状金属构件(9)和配线部件(7)构成,所述板状金属构件构成配置于磁性芯体(4)的腿部(4b)的多个线圈,所述配线部件将板状金属构件(9)的端子(9a)之间连接,线圈体(3)在多个板状金属构件(9)之间以及板状金属构件(9)与磁性芯体(4)之间夹装有绝缘构件(14),板状金属构件(9)与绝缘构件(14)通过一体成型而接合。(A power conversion device is provided, which can ensure heat dissipation and realize the miniaturization, lightweight and low cost of the device. An electromagnetic induction device (1) comprises: a magnetic core (4) constituting a closed magnetic circuit; and a coil body (3) that is configured from a plate-shaped metal member (9) that configures a plurality of coils arranged on the leg portions (4b) of the magnetic core (4), and a wiring component (7) that connects the terminals (9a) of the plate-shaped metal member (9), wherein an insulating member (14) is interposed between the plurality of plate-shaped metal members (9) and between the plate-shaped metal member (9) and the magnetic core (4) in the coil body (3), and the plate-shaped metal member (9) and the insulating member (14) are joined by integral molding.)

1. A power conversion apparatus, characterized in that the power conversion apparatus is mounted with an electromagnetic induction device comprising:

a magnetic core constituting a closed magnetic circuit; and

a coil body including a plate-shaped metal member constituting a plurality of coils arranged so as to surround the leg portions of the magnetic core, and a wiring member connecting the terminal portions of the plate-shaped metal member,

the coil body is configured such that an insulating member is interposed between the plurality of sheet metal members and between the sheet metal members and the magnetic core, and the sheet metal members and the insulating member are joined by integral molding.

2. The power conversion apparatus according to claim 1,

the electromagnetic induction device is attached to a housing of the power conversion apparatus, and a part or the whole of the electromagnetic induction device is enclosed in the housing by a potting material.

3. The power conversion apparatus according to claim 1 or 2,

the magnetic core constituting the closed magnetic circuit is U-shaped, and the coil bodies are disposed on both leg portions of the magnetic core.

4. The power conversion apparatus according to any one of claims 1 to 3,

the coil body includes a primary coil portion and a secondary coil portion, and the plate-shaped metal members of the primary coil portion and the plate-shaped metal members of the secondary coil portion are alternately arranged in a lamination direction.

5. The power conversion apparatus according to claim 4,

the coil body is a laminated body of the primary coil part and the secondary coil part, and the laminated body of the primary coil part and the secondary coil part is formed by integrally joining the plate-shaped metal member and the insulating member, which are integrally processed.

6. The power conversion apparatus according to claim 5,

a plane of one side of the plate-shaped metal member of the primary coil portion and the secondary coil portion is exposed.

7. The power conversion apparatus according to claim 5 or 6,

the primary coil part and the secondary coil part respectively include two layers of the plate-shaped metal members.

8. The power conversion apparatus according to any one of claims 5 to 7,

the coil body is a laminated body in which the laminated body of the plurality of primary coil parts and the secondary coil parts is integrally molded and joined by an external insulating member.

9. The power conversion apparatus according to any one of claims 5 to 8,

the coil body is a laminated body of the primary coil part and the secondary coil part which are integrally formed with a required number of turns.

10. The power conversion apparatus according to claim 4,

the plate-shaped metal member of the primary coil part and the plate-shaped metal member of the secondary coil part are joined to the insulating member by being simultaneously integrally molded.

11. The power conversion apparatus according to claim 3,

the coils of the coil bodies arranged on the two leg portions of the magnetic core are electrically connected in series.

12. The power conversion apparatus according to claim 3,

the coils of the coil bodies arranged on the two leg portions of the magnetic core are electrically connected in parallel.

13. The power conversion apparatus according to claim 2,

the housing to which the electromagnetic induction device is mounted is made of a metal material.

14. The power conversion apparatus according to claim 2 or 13,

the housing to which the electromagnetic induction device is mounted is a case of the power conversion apparatus.

15. The power conversion apparatus according to any one of claims 2, 13, and 14,

at the case where the electromagnetic induction apparatus is mounted, a pedestal is provided on a bottom surface of the case corresponding to the leg portion of the magnetic core outside the coil body.

16. The power conversion apparatus according to claim 15,

the leg portion of the magnetic core outside the coil body is in contact with the pedestal of the bottom surface of the case.

17. The power conversion apparatus according to claim 2,

a lower surface of the coil body constituting the electromagnetic induction device is in contact with a bottom surface of the case.

18. The power conversion apparatus according to claim 2,

the lower surface of the coil body constituting the electromagnetic induction device is not in contact with the bottom surface of the case.

19. The power conversion apparatus according to claim 1,

the wiring member is constituted by a printed wiring board having a conductive wiring pattern for connecting the terminal portions.

20. The power conversion apparatus according to claim 1,

the wiring member is constituted by a bus bar module in which bus bars are integrally formed by an insulating member, and the bus bars connect the terminal portions formed of metal plates.

21. The power conversion apparatus according to claim 2,

the wiring member is constituted by a printed wiring board having a conductive wiring pattern for connecting the terminal portions.

22. The power conversion apparatus according to claim 2,

the wiring member is constituted by a bus bar module in which bus bars are integrally formed by an insulating member, and the bus bars connect the terminal portions formed of metal plates.

23. The power conversion apparatus according to any one of claims 2, 21, and 22,

the wiring member is disposed on the upper portion of the housing.

24. The power conversion apparatus according to any one of claims 2, 21, and 22,

the wiring member is disposed at a lower portion of the housing.

25. The power conversion apparatus according to claim 2,

the potting material enclosing the electromagnetic induction device in the housing is a resin material having insulation properties and thermal conductivity.

26. The power conversion apparatus according to any one of claims 5 to 9,

the coil bodies disposed on the two leg portions of the magnetic core are integrated.

27. The power conversion apparatus according to any one of claims 4 to 10,

the power conversion device includes the coil body having a structure in which a part of the primary coil portions or a part of the secondary coil portions are stacked on top of each other without being alternated.

28. The power conversion apparatus according to any one of claims 4 to 10,

the power conversion device is in the following state: the terminal portions of the primary coil portions arranged in the two leg portions are close to each other, and the terminal portions of the secondary coil portion are spaced apart from each other.

29. The power conversion apparatus according to any one of claims 4 to 10,

the power conversion device is in the following state: the terminal portions of the primary coil portions arranged in the two leg portions are separated from each other, and the terminal portions of the secondary coil portion are close to each other.

Technical Field

The present application relates to a power conversion apparatus.

Background

Power conversion devices mounted in electric vehicles and hybrid vehicles are required to be compact and lightweight. In recent years, particularly in electric vehicles, there is a strong tendency to increase the battery capacity for the purpose of increasing the cruising distance, and it is necessary to increase the output of the in-vehicle charger.

When the output of the in-vehicle charger is increased, it is necessary to increase the current amount from the commercial ac power supply on the input side. Thus, the amount of current flowing in the coil portions of the transformer and the reactor constituting the in-vehicle charger is increased, and the amount of heat generation is also increased. Therefore, even if the output of the in-vehicle charger is increased, it is important to efficiently radiate heat from the coil.

In addition, for the purpose of improving fuel efficiency in vehicles, expanding the vehicle interior space, reducing the cost, and the like, power conversion devices such as in-vehicle chargers are required to be downsized and lightened. Therefore, among the components constituting the power conversion device, it is important to reduce the size and weight of the components. Increasing the driving frequency is an effective means for downsizing the electromagnetic induction device constituting the power conversion device. Further, the electromagnetic induction device is downsized due to the higher frequency, and the power conversion device can also be downsized and lightened. However, when the driving frequency is increased, the amount of heat generated from the core and the coil in the electromagnetic induction device increases, and therefore, it is important to efficiently dissipate the heat.

As an electromagnetic induction device having excellent heat dissipation properties, there is disclosed a reactor in which a reactor main body is housed in an aluminum case, the reactor main body is sealed with a sealing resin having high thermal conductivity, and the reactor is formed into a non-wound tubular structure, thereby efficiently dissipating heat (for example, patent document 1).

However, in the manufacturing process, the coil portion needs to be pressed against the case by a fixing jig, and there is a problem that the thickness of the sealing resin varies greatly, and the heat dissipation in the coil is reduced.

In contrast, in order to suppress heat dissipation and structural characteristic variation, an electromagnetic induction device including a coil portion and an insulating member is disclosed, the coil portion being configured by a plurality of C-shaped plate-shaped metal members and a pattern of a printed wiring board (for example, patent document 2).

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2009-94328 (paragraphs [0012] to [0014] and FIG. 1)

Patent document 2: japanese patent No. 6150844 publication (paragraphs [0013], [0018], [0052] and FIG. 1)

In the electromagnetic induction device disclosed in patent document 2, since the plate-shaped metal member forming the coil is attached to the recess of the insulating member, a gap is generated between the plate-shaped metal member and the insulating member, which causes a problem of lowering heat dissipation of heat loss generated in the coil.

Disclosure of Invention

The present application discloses a technique for solving the above-described problems, and an object thereof is to provide a power conversion device that can efficiently dissipate heat loss generated and increased in an electromagnetic induction device, and that can achieve reduction in size, weight, and cost.

The power conversion apparatus disclosed in the present application is provided with an electromagnetic induction device, the electromagnetic induction device includes:

a magnetic core constituting a closed magnetic circuit; and

a coil body composed of a plate-shaped metal member constituting a plurality of coils arranged so as to surround leg portions of the magnetic core, and a wiring member connecting terminal portions of the plate-shaped metal member,

in the coil body, insulating members are interposed between the plurality of plate-shaped metal members and between the plate-shaped metal members and the magnetic core, and the plate-shaped metal members and the insulating members are joined by integral molding.

According to the power converter disclosed in the present application, since the heat dissipation of the coil can be improved and the heat dissipation can be ensured even in the case of a higher frequency and a higher output, the power converter can be reduced in size, weight, and cost.

Drawings

Fig. 1 is a circuit configuration diagram showing a main part of a power converter according to embodiment 1.

Fig. 2 is a perspective view of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 3 is an exploded perspective view of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 4 is a perspective view of a coil body of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 5 is a perspective view of a coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 6 is an internal perspective view of a coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 7 is a perspective view of a primary coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 8 is a perspective view of a secondary coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 9 is a perspective view of a secondary coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 10 is a perspective view of a plate-shaped metal member constituting a coil portion of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 11 is a horizontal sectional view of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 12 is a perspective view of a wiring member of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 13 is a front view of a wiring member of a coil body of an electromagnetic induction device in a power conversion apparatus according to embodiment 1.

Fig. 14 is an explanatory view of installation of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 15 is an explanatory view of installation of an electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 16 is an explanatory view of mounting of the power converter according to embodiment 1.

Fig. 17 is a front view of a modification of the wiring member of the coil body of the electromagnetic induction device in the power conversion apparatus according to embodiment 1.

Fig. 18 is an explanatory view of the installation of a modification of the electromagnetic induction device in the power conversion apparatus according to embodiment 1.

(symbol description)

100 power conversion devices;

1 an electromagnetic induction device;

3a coil body;

3a through hole;

4a magnetic core;

a 4a U type magnetic core;

4b a leg portion;

4c a butt joint surface;

4d rounding off the corner;

6 coil parts;

7. 7A wiring member;

7a substrate;

7b1, 7b2 through holes;

7c1, 7c2, 7f1 pads;

7d1, 7d2, 7e1, 7e2, 7g1, 7h1 wiring patterns;

8 an outer insulating member;

9a plate-like metal member for a primary coil;

9a, 10a terminal portions;

9b a plane;

9c a conductive portion;

9d penetrating the hole;

10a plate-like metal member for a secondary coil;

11 a primary coil portion;

12. 12A secondary coil part;

14 an insulating member;

14d through the hole;

15 an external terminal;

16a housing;

16a housing bottom surface;

16b a first level difference portion;

16c a second level difference portion;

17, encapsulating material;

18a housing;

18a inner bottom surface;

18b small chamber walls;

18c a refrigerant passage section;

18d1 refrigerant supply pipe;

18d2 refrigerant discharge tube;

19 a cover;

20 a filter circuit section;

21 a capacitor section;

22 a reactor section;

23 a switching element;

24 a control substrate section;

25 a cooling pump;

31 an insulating resin;

110 a switching circuit section;

111 a switching element;

120 transformer circuit part;

130 a rectifier circuit section;

a 131 diode;

140 a smoothing circuit section;

141 smoothing reactors;

142 a smoothing capacitor;

a positive side input terminal;

b a negative side input terminal;

c. d an output terminal.

Detailed Description

Embodiment mode 1

Embodiment 1 relates to a power conversion apparatus mounted with an electromagnetic induction device including: a magnetic core constituting a closed magnetic circuit; and a coil body including a plate-shaped metal member and a wiring member, the plate-shaped metal member forming a plurality of coils arranged on a leg portion of the magnetic core, the wiring member connecting terminal portions of the plate-shaped metal member, the coil body having insulating members interposed between the plurality of plate-shaped metal members and between the plate-shaped metal member and the magnetic core, the plate-shaped metal member and the insulating members being joined by integral molding.

Hereinafter, the configuration and operation of the power conversion device according to embodiment 1 will be described with reference to fig. 1 to 18, in which fig. 1 is a circuit configuration diagram showing a main part of the power conversion device, fig. 2 is a perspective view of an electromagnetic induction device, fig. 3 is an exploded perspective view of the electromagnetic induction device, fig. 4 is a perspective view of a coil body of the electromagnetic induction device, fig. 5 is a perspective view of a coil portion of the coil body, fig. 6 is an internal perspective view of the coil portion of the coil body, fig. 7 is a perspective view of a primary coil portion of the coil body, fig. 8 and 9 are perspective views of a secondary coil portion of the coil body, fig. 10 is a perspective view of a plate-like metal member constituting the coil portion of the coil body, fig. 11 is a horizontal sectional view of the electromagnetic induction device, fig. 12 is a perspective view of a wiring member of the coil body of the electromagnetic induction device, and fig. 13 is a main view of a wiring member of the coil body of the electromagnetic induction device, fig. 14 and 15 are explanatory views of mounting of the electromagnetic induction device, fig. 16 is an explanatory view of mounting of the power conversion apparatus, fig. 17 is a front view of a modification of the wiring member of the coil body of the electromagnetic induction device, and fig. 18 is an explanatory view of mounting of the modification of the electromagnetic induction device. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and redundant description thereof is omitted.

First, the overall configuration of the power converter 100 according to embodiment 1 will be described with reference to fig. 1, which is a circuit configuration diagram of a main part of the power converter 100.

The power conversion device 100 is assumed to be a power conversion device such as an in-vehicle charger mounted on an electric vehicle or a hybrid vehicle.

The power conversion device 100 includes a hard-switching full-bridge DC/DC converter unit in an in-vehicle charger, and fig. 1 shows a circuit configuration of the DC/DC converter unit.

The power converter 100 converts and boosts a commercial input ac voltage of 100 to 200V into a dc voltage of about 300 to 400V, which is a driving battery voltage of an electric vehicle, for example.

The power conversion apparatus 100 includes, in addition to the DC/DC converter section: an AC/DC converter section; a converter section between the AC/DC converter section and the DC/DC converter section; and a filter circuit section, but are omitted in fig. 1. The filter circuit unit is provided in the input unit and the output unit of the power conversion device 100.

The DC/DC converter portion includes a switching circuit portion 110, a transformer circuit portion 120, a rectifier circuit portion 130, and a smoothing circuit portion 140.

The DC/DC converter unit has a positive input terminal a and a negative input terminal b on the input side, and has an output terminal c and an output terminal d on the output side.

Next, the configuration of the main circuit section of the power converter 100 will be described.

The switching circuit unit 110 converts an input dc voltage applied between the positive input terminal a and the negative input terminal b into an ac voltage by a switching operation using a plurality of switching elements 111 such as MOSFETs (metal oxide semiconductor field effect transistors) and IGBTs (insulated gate bipolar transistors).

The transformer circuit section 120 includes an electromagnetic induction device 1, the electromagnetic induction device 1 having a primary coil section 11 on a primary side and a secondary coil section 12 on a secondary side.

The transformer circuit unit 120 has a transforming function, and boosts an input voltage converted into an alternating current by the switching circuit unit 110 to a voltage of a battery connected to the output terminal c and the output terminal d while maintaining insulation.

In the transformer circuit unit 120, the transformation ratio is determined based on the ratio of the number of turns of the secondary coil unit 12 to the number of turns of the primary coil unit 11.

In embodiment 1, the number of turns of the secondary coil portion 12 is set to be larger than the number of turns of the primary coil portion 11.

Although the electromagnetic induction device 1 is generally called a transformer, an electromagnetic induction device will be described in the description of embodiment 1.

The rectifier circuit portion 130 includes a plurality of diodes 131 as rectifier elements.

In this example, the rectifier circuit unit 130 includes four diodes, and converts the high-voltage ac voltage output from the secondary coil unit 12 of the transformer circuit unit 120 into a dc voltage.

The smoothing circuit section 140 includes a smoothing reactor 141 and a smoothing capacitor 142. The smoothing circuit unit 140 smoothes the dc voltage rectified by the rectifier circuit unit 130, and outputs the smoothed voltage to the output terminal c and the output terminal d.

Next, the structure and function of the electromagnetic induction device 1 will be described with reference to fig. 2 to 12.

Fig. 2 is a perspective view showing the electromagnetic induction device 1 of the power conversion apparatus 100, and fig. 3 is an exploded perspective view of the electromagnetic induction device 1.

The electromagnetic induction device 1 includes a coil body 3 and a magnetic core 4.

First, the structure of the magnetic core 4 will be mainly described with reference to fig. 3.

The magnetic core 4 is composed of two U-shaped magnetic cores 4a, and a closed magnetic circuit is formed by abutting the two U-shaped magnetic cores 4 a.

The U-shaped magnetic core 4a has a leg 4b and an abutment surface 4 c. The coil body 3 is disposed so as to surround the leg portion 4b of the U-shaped magnetic core 4 a.

Further, the magnetic core 4 includes a rounded corner portion 4d in a rounded corner shape.

The U-shaped magnetic core 4a is made of a magnetic material such as ferrite. The leg portions 4b are inserted into two through holes 3a provided in the coil body 3 from both side surfaces of the coil body 3, and the U-shaped magnetic core 4a is attached to the coil body 3.

In a state where the butting faces 4c in the two U-shaped magnetic cores 4a are in contact with each other, the coil body 3 and the magnetic core 4 are temporarily fixed by the adhesive tape 5 as shown in fig. 2. Thus, the abutting surfaces 4c of the two U-shaped magnetic cores 4a are in contact, thereby constituting a closed magnetic circuit of the magnetic core 4.

As described with reference to fig. 13 and 14, the electromagnetic induction device 1 is attached to the case 16, and is filled with the potting material 17 and cured, whereby the magnetic core 4 and the coil body 3 are fixed to the power conversion device 100.

Next, the structure of the coil body 3 will be described with reference to fig. 4 to 10.

The coil body 3 includes a coil portion 6 and a wiring member 7.

Fig. 6 shows a state in which the external insulating member 8 is removed from the state of fig. 5, and the external insulating member 8 is omitted for the sake of easy understanding of the internal structure of the coil portion 6.

The coil part 6 includes a primary coil part 11 on the primary side, secondary coil parts 12, 12A on the secondary side, and an external insulating member 8.

The structure of the primary coil portion 11 and the secondary coil portions 12 and 12A will be described with reference to fig. 6 to 10.

As shown in fig. 6 and 7, the primary coil portion 11 is composed of two primary coil plate-like metal members 9 and an insulating member 14.

In addition, the primary coil plate-shaped metal member 9 is described as a plate-shaped metal member 9 unless otherwise explicitly stated.

The plate-shaped metal member 9 will be explained.

As shown in fig. 7 and 10, the plate-like metal member 9 has a C-shape and has terminal portions 9a at its end portions, and the terminal portions 9a are disposed at asymmetric positions with respect to the central axis. In fig. 7, the two plate-like metal members 9 have the same shape and are arranged so that the terminal portions 9a thereof are close to each other.

The terminal portions 9a are provided with a predetermined distance therebetween, that is, an insulation distance corresponding to a voltage drop generated between the primary coils.

Further, the two plate-like metal members 9 are disposed so as to ensure a predetermined insulation distance also in the conductive portion 9c as shown in fig. 7.

The plate-like metal member 9 is made of a metal material such as copper or aluminum, and is integrally processed to form a conductive portion 9c and a terminal portion 9a having a predetermined width and thickness.

The resistance of the sheet metal member 9 is adjusted by the specific resistance, the sheet width, and the sheet thickness, which are different depending on the material type. The plate-like metal member 9 is produced by a process of punching a flat metal plate with a press die or the like.

Instead of punching out with a press die, a flat metal plate may be subjected to laser processing, etching, or the like.

Further, the plate-shaped metal member 9 is provided with a through hole 9d so that the leg portion 4b of the U-shaped magnetic core 4a can be inserted.

The insulating member 14 will be explained.

The insulating member 14 is made of an insulating resin material such as PPS (Polyphenylene sulfide), PET (polyethylene terephthalate), PBT (Polybutylene terephthalate), and epoxy resin.

Further, the plate-shaped metal member 9 and the insulating member 14 are integrated and joined by insert molding. Specifically, the plate-like metal member 9 is integrated by injection molding of a molten insulating resin material in a state of being disposed in a mold for insert molding.

When the plate-like metal member 9 and the insulating member 14 are integrated by insert molding, the plate-like metal member 9 is integrated in such a manner that the flat surface 9b on one side is exposed on the surface.

Further, the primary coil portion 11 formed by integrally molding the plate-shaped metal member 9 and the insulating member 14 is provided with a through hole 14d into which the leg portion 4b of the U-shaped magnetic core 4a can be inserted.

The secondary coil portions 12 and 12A will be described mainly with reference to fig. 8 and 9.

The secondary coil portion 12 is composed of two secondary coil plate-like metal members 10 and an insulating member 14. Here, the plate-like metal member for secondary coil 10 is made of the same material and has the same shape as the plate-like metal member for primary coil 9.

However, unlike the primary coil portion 11, the secondary coil portion 12 is arranged in a direction in which the terminal portions 10a of the plate-shaped metal member 10 are separated, not in a direction in which the terminal portions 10a of the plate-shaped metal member 10 are close. The secondary coil portion 12 is integrated with the insulating member 14 by insert molding in a state where the terminal portions 10a of the plate-shaped metal member 10 are separated.

Further, the secondary coil portion 12 formed by integrally molding the plate-shaped metal member 10 and the insulating member 14 is provided with a through hole 14d into which the leg portion 4b of the U-shaped magnetic core 4a can be inserted.

The secondary coil portion 12A is composed of two plate-like metal members 10 for secondary coils and an insulating member 14, similarly to the secondary coil portion 12. The insulating member 14 has a larger thickness in the stacking direction than the secondary coil portion 12. The reason for this will be described next.

In addition, the plate-shaped metal member 10 for the secondary coil is described as a plate-shaped metal member 10, unless otherwise explicitly indicated.

As shown in fig. 6, the primary coil part 11 and the secondary coil part 12 are alternately stacked and arranged to form the coil part 6.

In embodiment 1, a step-up transformer having a secondary winding with a larger number of turns than a primary winding is assumed as a transformer configuration. Therefore, in embodiment 1, the secondary coil portions 12 are disposed at both ends in the stacking direction.

Specifically, a step-up transformer having ten turns of the primary winding and fourteen turns of the secondary winding is assumed. In terms of the turn ratio, the secondary coil portion 12 is continuously arranged in the lamination.

Although the coil part 6 in embodiment 1 has a structure in which the primary coil part 11 and the secondary coil part 12 are alternately stacked, as shown in fig. 6, only the secondary coil part 12A is adjacent to the secondary coil part 12.

Thus, in the case where the wall thickness of the insulating member 14 is the same as that of the secondary coil section 12, an interval between through holes in the wiring member 7 (an interval in the up-down direction in fig. 13) described later becomes small, and pattern arrangement becomes difficult. In order to solve the above problem, the insulating member 14 is thickened only in the secondary coil portion 12A, and the through hole interval is secured.

The coil portion (fig. 6) in which the primary coil portion 11 and the secondary coil portions 12 and 12A are stacked is insert-molded again with the external insulating member 8, and the respective coil portions (the primary coil portion 11 and the secondary coil portions 12 and 12A) are integrally molded and integrated to form the coil portion 6 (fig. 5). Further, the respective coil portions (the primary coil portion 11, the secondary coil portions 12, 12A) are joined to the external insulating member 8 by integral molding.

Here, the external insulating member 8 is made of the same insulating resin material as the insulating member 14.

Fig. 11 is a horizontal cross-sectional view of fig. 2, taken along a horizontal plane, with the center point of the magnetic core 4 in the vertical direction cut off, and viewed from above.

As shown in fig. 11, in the electromagnetic induction apparatus 1, the outer insulating member 8 is disposed and joined to the outer peripheries of the insulating members 14 in the primary coil portion 11 and the secondary coil portion 12. Therefore, the interface between the primary coil portion 11 and the secondary coil portion 12 can be cut by the external insulating member 8, and the surface insulation between each coil portion and the magnetic core 4 can be reliably performed.

Next, the wiring member 7 will be described with reference to fig. 12 and 13.

The wiring member 7 in embodiment 1 is constituted by a printed wiring board using a multilayer substrate having insulation properties such as a glass epoxy substrate.

The wiring member 7 is provided with a primary coil via 7b1, a secondary coil via 7b2, a primary coil pad 7c1, and a secondary coil pad 7c2 on a substrate 7a made of glass epoxy resin. The substrate 7a is provided with a primary coil wiring pattern 7d1, a secondary coil wiring pattern 7d2, and a primary coil wiring pattern 7e1 and a secondary coil wiring pattern 7e2 between the substrate and the external terminals.

The via holes, the pads, and the wiring patterns are made of a metal body such as copper and aluminum, and the wiring patterns are disposed not only on the surface layer but also on the inner layer (not shown). The through hole is a hole in the substrate 7a, and a conductor is arranged inside the hole to electrically connect the surface layer and the inner layer in the multilayer substrate.

The primary coil through hole 7b1 and the secondary coil through hole 7b2 are formed in a long hole shape. The terminal portions 9a and 10a of the plate-like metal members 9 and 10 in the coil portion 6 are inserted into the primary coil through-holes 7b1 and the secondary coil through-holes 7b2 in the wiring member 7, and soldered in a state where the terminal portions 9a and 10a protrude from the substrate 7 a. As a result, the coil portion 6 and the wiring member 7 are electrically and structurally connected.

Further, the plate-like metal members 9 and 10 having the C-shape are connected to the through holes and connected to the wiring patterns 7d1 and 7d2 wired between the pads. Therefore, the plate-like metal members 9 and 10 and the wiring pattern constitute a transformer winding, and the leg portion 4b of the magnetic core 4 is wound by a predetermined number of turns.

In addition, the connection of the electromagnetic induction device 1 to the outside is made through the external terminal 15.

Further, as shown in fig. 13, since the primary coil portions 11 and the primary coil portions 12 are alternately arranged in a stacked manner, the primary coil through holes and the secondary coil through holes are arranged in a manner shifted by a in the stacking direction. In order to ensure insulation between the primary side and the secondary side, the pads for the primary coil and the secondary coil are arranged at a distance of B, between the pads and the pattern, and between the pattern and the pattern.

As shown in fig. 13, the coil portions 6 arranged on the two leg portions 4b of the magnetic core 4 are formed of wiring patterns so as to be connected in series together with the primary coil portion 11 and the secondary coil portion 12.

An example of a case where the electromagnetic induction device 1 is mounted on a metal case (housing) of the power conversion apparatus 100 will be described with reference to fig. 14 and 15.

The electromagnetic induction device 1 is mounted on the housing 16 constituting the power conversion apparatus 100.

In the electromagnetic induction device 1, the wiring member 7 is attached to the housing 16 made of aluminum or the like so as to be positioned at an upper portion, and then, the housing 16 and the electromagnetic induction device 1 are structurally bonded and fixed by filling and curing the wiring member with the potting material 17.

The potting material 17 is made of a resin material having desired thermal conductivity, insulation property, and hardness, such as silicone resin, epoxy resin, or urethane resin. As shown in fig. 15, the filling height of the potting material 17 in the case 16 is set to be filled to the upper portion of the coil body 3.

In fig. 15, the entire electromagnetic induction device 1 is filled and sealed, but a part of the electromagnetic induction device 1 may be filled and sealed. In fig. 15, the terminal portions 9a and 10a of the plate-shaped metal member for primary coil 9 and the plate-shaped metal member for secondary coil 10 of the coil body 3 are partially exposed from the potting material 17, but may be completely filled and sealed.

In the case 16, a case bottom surface 16a corresponding to the leg portion 4b of the magnetic core 4 outside the coil body 3 is provided with a first level difference portion 16b rising from the case bottom surface 16a at two locations as a pedestal of the magnetic core 4. By providing the first level difference portion 16b, the thickness of the potting material 17 between the magnetic core and the housing in the height direction can be reduced.

In embodiment 1, the lower surface of the leg portion 4b of the magnetic core 4 is in contact with the first stepped portion 16b of the case 16.

In embodiment 1, the lower surface of the coil body 3 of the electromagnetic induction device 1 is not in contact with the case bottom surface 16a of the case 16, and a potting material 17 is filled between the lower surface of the coil body 3 and the case bottom surface 16a of the case 16. However, the lower surface of the coil body 3 of the electromagnetic induction device 1 may be in contact with the case bottom surface 16a of the case 16.

Further, second level difference portions 16c are provided at the four corners of the case 16 so as to surround the rounded corner portions 4d provided to the magnetic core 4. Therefore, when the electromagnetic induction device 1 is attached to the housing 16, the clearance between the rounded portion 4d of the magnetic core 4 and the housing 16 is reduced.

Next, an operation of the power converter 100 according to embodiment 1 will be described.

In the power converter 100 according to embodiment 1, the plate-shaped metal members 9 and 10 constituting the coil portion 6 of the coil body 3 and the insulating member 14 are integrated and joined by insert molding. Therefore, the air layer between the plate-shaped metal member and the insulating member can be eliminated and brought into close contact with each other, and therefore, the heat dissipation properties of the primary coil portion 11 and the secondary coil portion 12 can be improved.

The electromagnetic induction device 1 is mounted in a metal case 16 and filled with a potting material 17. Therefore, the coil body 3 and the magnetic core 4 are connected to the case 16 together via the potting material 17, so that it is possible to further improve heat dissipation.

Therefore, even when the power conversion device 100 has a higher frequency and a higher output, heat dissipation can be ensured, and the electromagnetic induction device 1 and the power conversion device 100 can be reduced in size, weight, and cost.

In embodiment 1, the U-shaped magnetic core 4a is used, the primary coil portion 11 and the secondary coil portion 12 are disposed on the two leg portions 4b, and the coil portions of the two leg portions 4b are connected in series to be wired. Therefore, the number of turns in the coil portion at the leg portion of the magnetic core can be reduced by half as compared with the structure of the electromagnetic induction device as in the conventional patent document 2. Therefore, the size of the coil section as the electromagnetic induction device 1 in the stacking direction can be reduced, and the power conversion apparatus 100 can be made small and light.

Further, since the coil portions 6 can be arranged at the two leg portions 4b in the magnetic core 4, the number of turns can be easily increased, and along with this, the sectional area of the core can be reduced.

Further, even with respect to a technical problem that the heat generation density in the magnetic core becomes significantly large in the case of increasing the frequency of the electromagnetic induction apparatus, the number of turns can be increased while suppressing an increase in the size of the coil portion 6 of the electromagnetic induction apparatus 1. Therefore, the magnetic flux density of the magnetic core 4 can be reduced, and an increase in the heat generation density of the magnetic core 4 can be suppressed while achieving a higher frequency.

Further, since the coil portion 6 is disposed so as to surround the leg portion 4b of the magnetic core 4, the bottom surface and the side surface of the coil body 3 are exposed, and the exposed surface area can be increased as compared with an electromagnetic induction device configured by an outer core such as an EE core. Therefore, heat dissipation from the coil body 3 through the potting material can be performed more efficiently.

Further, in the conventional electromagnetic induction apparatus, it is necessary to mount the plate-like metal member to the recess of the insulating member, and there is a technical problem that the number of parts increases and productivity cannot be improved. However, in the electromagnetic induction apparatus of embodiment 1, the plate-shaped metal members 9, 10 are integrally molded with the insulating member 14 by insert molding, and further, the plurality of primary coil sections 11 and the secondary coil section 12 are integrated by insert molding. Therefore, productivity including handling at the time of manufacturing can be improved, and the number of parts can be reduced.

Further, when the primary coil portion 11 and the secondary coil portion 12 are laminated, when the secondary coil portions are continuous with each other, the thickness of the secondary coil portion 12 closest to the end portion is increased, so that it is not necessary to make the through hole interval in the wiring member different from the through hole interval in the other portion, and the wiring pattern can be easily arranged.

Further, the plate-shaped metal members 9, 10 having the same shape are used for the primary coil portion 11 and the secondary coil portion 12, and the two plate-shaped metal members 9, 10 are integrally insert-molded. Therefore, as compared with the case of insert molding one plate-shaped metal member, the number of components to be used as the coil portion can be reduced by half, and productivity and cost reduction can be achieved.

In addition, the coil unit 6 is formed by integrating the plate-shaped metal members 9 and 10 by insert molding, and the coil is not formed by a conventional winding method of a circular wire or a flat wire. Therefore, dimensional accuracy can be improved, and variations in electrical and structural characteristics and variations in heat dissipation characteristics can be suppressed. Further, since variation in characteristics is suppressed, manufacturing management is facilitated, and manufacturing cost can be reduced.

Next, an example of a case where the electromagnetic induction device 1 is mounted so as to include other main circuit portions of the power conversion apparatus 100 will be described with reference to fig. 16.

Fig. 16 is an exploded perspective view showing a mounted state of a main circuit portion of the power converter 100.

The power conversion apparatus 100 includes: a case 18, the case 18 having an upper portion opened; and a cover 19, the cover 19 being fixed to the case 18 by a screw or the like, and closing an upper opening of the case 18 to hermetically seal the inside of the case 18.

First, the structure of the housing 18 will be explained.

The case 18 includes an inner bottom surface 18a, a small chamber wall 18b, a refrigerant flow path portion 18c, a refrigerant supply pipe 18d1, and a refrigerant discharge pipe 18d 2.

A small chamber wall 18b is provided integrally formed with the inner bottom surface 18a of the housing 18. Further, the refrigerant flow path portion 18c is integrally provided on the inner bottom surface 18a of the case 18.

The electromagnetic induction device 1 is mounted in a small chamber wall 18b provided on an inner bottom surface 18a of the housing 18. The electromagnetic induction device 1 is mounted in the small chamber wall 18b of the housing 18, and then filled with the potting material 17, cured, thereby structurally bonding the electromagnetic induction device 1 and the housing 18.

Components such as filter circuit unit 20, capacitor unit 21, and reactor unit 22 are mounted on inner bottom surface 18a of case 18. In fig. 16, an input connector for supplying electric power to the power conversion device 100, an output connector for outputting the converted electric power from the power conversion device 100, and a control connector for controlling the power conversion device 100 are omitted.

The refrigerant flow path portion 18c is disposed on the inner bottom surface 18a of the case 18 so as to surround the electromagnetic induction device 1 and the reactor portion 22. The refrigerant supply tube 18d1 and the refrigerant discharge tube 18d2 are connected to the refrigerant flow path portion 18 c.

The refrigerant supply tube 18d1 and the refrigerant discharge tube 18d2 are connected to a cooling pump 25 (not shown) installed in the vehicle, and the refrigerant from the cooling pump 25 circulates through the refrigerant flow path portion 18 c.

A plurality of switching elements 23 are attached to the upper portion of the refrigerant passage portion 18 c.

A control board portion 24 is mounted on the upper portion of the components such as the switching element 23 and the reactor portion 22 mounted in the case 18, and the control board portion 24 controls the electric wiring between the components and the driving of the power conversion device 100.

The terminals of the respective members are inserted into through holes (not shown) in the control substrate portion 24, and connected and wired by soldering or the like.

Here, the correspondence between the filter circuit unit 20, the capacitor unit 21, the reactor unit 22, and the switching element 23 and the respective main circuit units described with the overall configuration of the power conversion device 100 based on fig. 1 will be described.

The filter circuit section 20 corresponds to filter circuit sections (not shown) provided at an input section and an output section of the power conversion apparatus 100.

The capacitor section 21 corresponds to a capacitor section (not shown) between the AC/DC converter section and the DC/DC converter section.

The reactor section 22 corresponds to a smoothing reactor 141 of the smoothing circuit section 140 and a PFC (Power Factor Correction) reactor (not shown) of the AC/DC converter section of the Power conversion device 100.

The switching element 23 corresponds to the switching element 111 of the switching circuit section 110 and a switching element (not shown) of the AC/DC converter section.

The power conversion apparatus 100 configured as described above is used as a converter for supplying the output power of the electromagnetic induction device 1 to an external device (a battery for an electric vehicle, etc.), for example.

The refrigerant flow path portion 18c is disposed so as to surround the electromagnetic induction device 1 as a main heat generator and the reactor portion 22. Therefore, heat generated from the electromagnetic induction device 1 and the reactor section 22 is efficiently dissipated via the refrigerant flowing through the refrigerant flow path sections 18c on both sides. Further, the heat generated by the switching element 23 is radiated via the refrigerant flowing through the refrigerant passage portion 18 c. Therefore, the power conversion device 100 can be reduced in size, weight, and cost.

Here, the housing 18 is made of a metal material having the same required strength and thermal conductivity as the case 16 illustrated in fig. 14, such as an isostatically cast (cast) member of aluminum, magnesium, or a cutting member.

The small chamber wall 18b is formed in an inward shape to match the outer shape of the electromagnetic induction apparatus 1. Further, although not shown, similarly to the case 16 of fig. 14, a first step portion corresponding to the magnetic core 4 of the electromagnetic induction device 1 and a second step portion corresponding to the rounded portion 4d of the magnetic core 4 are integrally formed in the small chamber wall 18b of the case 18. Thus, the electromagnetic induction apparatus 1 can efficiently radiate heat to the cooler via the potting material 17 and via the first level difference portion and the second level difference portion.

In addition, a projection (not shown) provided with a positioning hole for positioning the electromagnetic induction device 1 to the case 18 may be provided in the small chamber wall 18b of the case 18.

By inserting a positioning pin (not shown) formed of the external insulating member 8 in the coil portion 6 of the electromagnetic induction device 1 into the positioning hole, the electromagnetic induction device 1 can be mounted to the case 18 with high accuracy.

Therefore, the thickness of the potting material between the coil body and the case and the thickness of the potting material between the magnetic core and the case can be suppressed from varying. Thus, unevenness in heat dissipation in the electromagnetic induction device 1 can be suppressed, so that miniaturization becomes further possible.

Next, a modified example of the wiring structure of the wiring member 7 described with reference to fig. 12 and 13 will be described with reference to fig. 17.

In fig. 12 and 13, a description is given of a case where the wiring structure of the wiring member 7 is a series connection. In the wiring member 7A of fig. 17, the wiring structure of the primary coil portion 11 is connected in parallel, and the wiring structure of the secondary coil portion 12 is connected in series.

For the purpose of distinguishing the wiring member 7 from fig. 12, the primary coil lands 7f1, the primary coil wiring traces 7g1, and the primary coil wiring traces 7h1 between the substrate and the external terminals are described.

According to the above configuration, since the primary coil portions 11 are connected in parallel, the current to be applied is halved as compared with the case of the series connection. Therefore, the heat generated in the primary coil portion 11 can be greatly reduced, and the heat dissipation can be further improved. Since the number of turns of the primary coil portion 11 is 1/2 (ten turns to five turns in the present modification) from when they are connected in series, the ratio of the number of turns in the primary coil portion 11 to the number of turns in the secondary coil portion 12 can be doubled, and the step-up ratio can be easily increased.

In the present modification, only the primary coil portion is connected in parallel, but both of the secondary coil portion 12 and the primary coil portion may be connected in parallel. Further, the primary coil portions 11 may be connected in series, and only the secondary coil portions 12 may be connected in parallel.

Next, a modification of the example in which the electromagnetic induction device 1 described in fig. 14 is attached to the housing 16 will be described with reference to fig. 18.

In fig. 14, the wiring member 7 is disposed so as to be located at an upper portion of the housing 16. In fig. 18, the wiring member 7 may be disposed on the bottom surface side, i.e., the lower portion of the case 16.

In this case, since the wiring member 7 is close to the bottom surface of the case, the heat dissipation property of the wiring member 7 can be improved, and it is not necessary to use a high heat-resistant material for the substrate 7 a. Therefore, the cost of the substrate 7a can be reduced, and the cost of the power conversion device 100 can be reduced.

In addition, the external terminal 15 is integrally molded with the insulating resin 31 to form an external terminal module, so that the assembling property can be improved.

In embodiment 1, the wiring member 7 constituting the coil body 3 is formed of a printed wiring board having a conductive wiring pattern. However, a bus bar (not shown) obtained by punching a land or a pattern from a metal plate (metal body such as copper or aluminum) may be used in such a manner that a portion corresponding to the through-hole portion is formed in a hole shape. Further, a member corresponding to the insulating substrate in the printed wiring board may be formed of an insulating resin, and the bus bar may be integrally molded with the insulating resin to form a bus bar module (not shown).

In this case, the heat resistance can be improved as compared with a printed wiring board, and cost reduction can be achieved.

In embodiment 1, the coil part 6 is configured by alternately stacking and disposing the primary coil parts 11 and the secondary coil parts 12, but the coil part 6 may be configured by stacking and disposing some of the primary coil parts 11 or some of the secondary coil parts 12 not alternately but in a superposed manner.

In embodiment 1, the terminal portions 9a of the primary coil portion 11 are in a close state and the terminal portions 10a of the secondary coil portion 12 are in a spaced state, but the terminal portions 9a of the primary coil portion 11 may be in a spaced state and the terminal portions 10a of the secondary coil portion 12 may be in a close state.

In embodiment 1, a transformer is used as the electromagnetic induction device, but a reactor can also be used.

In embodiment 1, the primary coil plate-shaped metal member 9 and the secondary coil plate-shaped metal member 10 are integrally molded with each other via the insulating member 14 to form the primary coil portion 11 and the secondary coil portions 12 and 12A, and the outer insulating member 8 is further integrally molded after being stacked. However, the primary coil plate-like metal member 9 and the secondary coil plate-like metal member 10 may be provided in advance in a molding die, and an insulating member (insulating resin) melted at a low pressure may be fluidized and molded (low-pressure molding). In this case, the coil portion can be manufactured by a single molding, and therefore, the number of parts and manufacturing cost can be reduced. Further, since it is possible to reduce the thickness of the resin as compared with the case of performing the secondary injection molding, further miniaturization can be achieved as an electromagnetic induction device.

As described above, the power conversion apparatus of embodiment 1 is mounted with an electromagnetic induction device including: a magnetic core constituting a closed magnetic circuit; and a coil body including a plate-shaped metal member and a wiring member, the plate-shaped metal member forming a plurality of coils arranged on a leg portion of the magnetic core, the wiring member connecting terminal portions of the plate-shaped metal member, the coil body including insulating members interposed between the plurality of plate-shaped metal members and between the plate-shaped metal member and the magnetic core, the plate-shaped metal member and the insulating members being joined by integral molding.

Therefore, in the power conversion device according to embodiment 1, since the heat dissipation property of the coil is improved, and the heat dissipation property can be ensured even when the frequency is increased and the output is increased, the size and weight of the device can be reduced and the cost can be reduced.

Further, although the present application describes exemplary embodiments, various features, aspects, and functions described in the embodiments are not limited to the specific embodiments, and can be applied to the embodiments alone or in various combinations.

Therefore, countless modifications not illustrated are assumed to be within the technical scope disclosed in the present application. For example, the case where at least one component is modified, the case where at least one component is added, or the case where at least one component is omitted is included.