Power module and power conversion apparatus having same

Abstract

The embodiment of the utility model provides a power module and an electric power conversion device with the same. The power module comprises a busbar, a plurality of capacitors, a plurality of phase units and a wire bar. The plurality of capacitors are arranged on one side of the busbar and are electrically connected with the busbar. The plurality of phase units are arranged on the other side of the busbar. The wire bar electrically connects the plurality of phase units to the busbar. The plurality of capacitors are arranged at intervals. The busbar is provided with a switching part. On the orthographic projection of the plane where the busbar is located, the plurality of capacitors and the switching part are arranged at intervals. And the wire bar is connected with the switching part. According to the scheme provided by the embodiment of the utility model, the wire bar is connected with the switching part of the busbar, and the orthographic projection of the switching part on the plane where the busbar is located and the plurality of capacitors are arranged at intervals. Therefore, the connection between the wire bar and the busbar does not need a connecting column, which is beneficial to shortening the circuit between the busbar and the phase unit, thereby reducing the stray inductance.

Description

Technical Field

[0001] The embodiments of the present utility model relate to the field of power electronics technology, and in particular, to a power module and a power conversion device having the same. Background Art

[0002] Power converters convert direct current (DC) to alternating current (AC) and are widely used in power generation, transmission, and consumption. For example, they can be found in electric vehicles, acting as a bridge between the battery system and the grid / load.

[0003] The power module is the core component of a power conversion device. It typically consists of a busbar and the phase units electrically connected to it. Long wiring between the busbar and the phase units creates significant stray inductance, which affects current balancing and negatively impacts the performance of the power conversion device. Utility Model Content

[0004] In view of this, embodiments of the present invention provide a power module and a power conversion device having the power module to solve the problem of high stray inductance caused by long lines between a busbar and a phase unit.

[0005] In one aspect, an embodiment of the present invention provides a power module. The power module includes a busbar, multiple capacitors, multiple phase units, and a busbar. The multiple capacitors are disposed on one side of the busbar and are electrically connected to the busbar. The multiple phase units are disposed on the other side of the busbar. The busbar electrically connects the multiple phase units to the busbar. The multiple capacitors are spaced apart. The busbar is provided with a transition portion. In an orthographic projection of the plane on which the busbar lies, the multiple capacitors are spaced apart from the transition portion. The busbar is connected to the transition portion.

[0006] In some embodiments, the plurality of capacitors form at least two columns of capacitor groups arranged at intervals, the capacitor group includes a plurality of capacitors arranged and extending along a first direction, and the transition portion is located between any two adjacent columns of capacitor groups.

[0007] In some embodiments, the plurality of phase units are arranged along a first direction.

[0008] In some embodiments, the power module includes two busbars, the two busbars comprising a first busbar and a second busbar. Each phase unit comprises a first component group and a second component group. Two transition portions spaced apart from each other are formed between the three columns of capacitor groups. The two transition portions comprise a first transition portion and a second transition portion. The first busbar electrically connects the first component group to the first transition portion, and the second busbar electrically connects the second component group to the second transition portion.

[0009] In some embodiments, the power module further includes a heat sink, and the first device group and the second device group are respectively disposed on opposite sides of the heat sink in a thickness direction.

[0010] In some embodiments, the heat sink and the busbar are arranged perpendicular to each other.

[0011] In some embodiments, each of the first and second busbars includes a first connection portion parallel to the busbar and a second connection portion parallel to the heat sink. The first connection portion of the first busbar is connected to the first adapter portion and extends away from the heat sink. The second connection portion of the first busbar is connected to the first component group. The first connection portion of the second busbar is connected to the second adapter portion and extends away from the heat sink. The second connection portion of the second busbar is connected to the second component group.

[0012] In some embodiments, the busbar includes a first connecting portion. The first connecting portion is stacked with the adapter portion, and an orthographic projection of the first connecting portion on the busbar at least partially overlaps with the adapter portion. The power module also includes a fastener that passes through the first connecting portion and the adapter portion to connect the first connecting portion to the adapter portion.

[0013] In some embodiments, the first connecting portion includes a first plate portion and a second plate portion stacked in sequence along a direction away from the busbar, and the busbar includes a first electrode plate, a second electrode plate, and a third electrode plate stacked in sequence along a direction away from the busbar. The first plate portion is connected to the second electrode plate through a first connecting structure, and the first electrode plate is provided with a avoidance hole for avoiding the first connecting structure. The first connecting structure includes two bent portions of the first plate portion and the second electrode plate bent toward each other, and the fastener passes through the two bent portions to connect the two. Additionally or alternatively, the second plate portion is connected to the first electrode plate through a second connecting structure, the first plate portion is provided with a avoidance hole for avoiding the second connecting structure, and the second connecting structure includes a boss of the second plate portion extending toward the first electrode plate, and the fastener passes through the boss and the first electrode plate to connect the two.

[0014] In some embodiments, the first connecting portion includes a first plate portion and a second plate portion stacked in sequence along a direction away from the busbar, and the busbar includes a first electrode plate, a second electrode plate, and a third electrode plate stacked in sequence along a direction away from the busbar. The first plate portion and the second electrode plate are connected by a first connecting structure, and the first electrode plate is provided with a avoidance hole for avoiding the first connecting structure. The first connecting structure includes two bent portions of the first plate portion and the second electrode plate bent toward each other, and the fastener passes through the two bent portions to connect the two. Additionally or alternatively, the second plate portion and the third electrode plate are connected by a second connecting structure, and the first plate portion, the first electrode plate, and the second electrode plate are all provided with avoidance holes for avoiding the second connecting structure. The second connecting structure includes two bosses extending toward each other of the second plate portion and the third electrode plate, and the fastener passes through the two bosses to connect the two.

[0015] In some embodiments, the plurality of first connection structures and the plurality of second connection structures are alternately arranged and spaced apart from each other.

[0016] In some embodiments, the first electrode plate is a positive electrode plate, the second electrode plate is a neutral electrode plate, and the third electrode plate is a negative electrode plate.

[0017] In some embodiments, a plurality of transition portions are provided between two adjacent columns of capacitor groups, and the plurality of transition portions are sequentially spaced apart along the first direction to form a gap region. In an orthographic projection of the plane where the busbar is located, part of the capacitors are located in the gap region.

[0018] In some embodiments, the transition portion has a width W, and the width W satisfies: 12 mm ≤ W ≤ 100 mm.

[0019] In some embodiments, any two adjacent capacitors have a distance D, and the distance D satisfies: D≥5mm.

[0020] In some embodiments, each phase unit includes a first component group, a second component group, and a third component group. The first component group and the second component group are electrically connected to the busbar and to the third component group. The third component group is electrically connected to the AC phase.

[0021] In some embodiments, the first device group, the second device group, and the third device group are all IGBT device groups, and each IGBT device group includes a plurality of IGBT devices connected in parallel.

[0022] In another aspect, the present invention further provides a power conversion device comprising a cabinet and a DC fuse, a DC disconnect switch, the power module provided in the aforementioned aspects, a reactor, an AC filter capacitor, and an AC circuit breaker housed therein and electrically connected in sequence.

[0023] According to the solution provided by the embodiment of the present invention, the busbar is connected to the busbar's transition portion, and the transition portion is spaced apart from the multiple capacitors in the orthographic projection of the busbar plane. This eliminates the need for connecting posts, shortening the wiring between the busbar and the phase units, thereby reducing stray inductance. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 FIG. 1 is a schematic structural diagram of a power module according to an embodiment of the present invention.

[0025] Figure 2 for Figure 1 Schematic diagram of the structure of the power module from another perspective.

[0026] Figure 3 for Figure 1 Schematic diagram of the structure of the power module from another perspective.

[0027] Figure 4 for Figure 1 Schematic diagram of the structure of a phase unit of the power module.

[0028] Figure 5 for Figure 1 Schematic diagram of the structure of multiple phase units and multiple heat sinks of a power module.

[0029] Figure 6 for Figure 1 Schematic diagram of the exploded structure of the busbar of the power module.

[0030] Figure 7 For the Figure 3 Schematic cross-sectional view taken along line AA in FIG.

[0031] Figure 8 For the Figure 3 Schematic cross-sectional view taken along line BB in FIG.

[0032] Figure 9 FIG. 1 is a schematic structural diagram of a power module according to another embodiment of the present invention.

[0033] Figure 10 for Figure 9 Schematic diagram of the structure of the power module from another perspective.

[0034] Figure 11 for Figure 9 Schematic diagram of the structure of the power module from another perspective.

[0035] Figure 12 for Figure 9 Schematic diagram of the structure in which the two busbars of the power module are connected together.

[0036] Figure 13 for Figure 9 Schematic diagram of the structure of multiple phase units and multiple heat sinks of a power module.

[0037] Figure 14 for Figure 12 Schematic diagram of the exploded structure of the two busbars.

[0038] Figure 15 For the Figure 11 Schematic cross-sectional view taken along line CC in FIG.

[0039] Figure 16 FIG. 1 is a structural diagram of a power conversion device according to an embodiment of the present invention.

[0040] Figure 17 FIG. 4 is a schematic structural diagram of a power conversion device according to another embodiment of the present invention. DETAILED DESCRIPTION

[0041] Numerous specific details are set forth below to provide an understanding of the structure, function, and use of the embodiments described in the specification and illustrated in the accompanying drawings. It is understood that the embodiments described and illustrated herein are non-limiting examples, and thus it is recognized that the specific structural and functional details disclosed herein are representative and exemplary. Modifications and changes may be made to these embodiments without departing from the scope of the claims.

[0042] An embodiment of the present invention provides a power module 10. Figures 1 to 8 For ease of understanding, the overall structure of the power module 10 is first described below. It should be understood that the structure of the power module 10 is not limited to the following description. For example, one or more of the elements (components or parts) described below may be omitted or replaced, and the layout relationships between them may be altered.

[0043] First reference Figures 1 to 5 The power module 10 may include a busbar 11 , a plurality of capacitors 12 , a plurality of phase units 13 , a plurality of AC terminals 14 , a plurality of line buses 15 , a plurality of gate plates 16 and a plurality of heat sinks 17 .

[0044] The busbar 11 can provide multiple DC terminals, namely a positive terminal, a negative terminal, and a neutral terminal, which can be referred to as the P terminal, the N terminal, and the O terminal, respectively. The positive terminal can be electrically connected to the positive terminal of a DC power source or a DC load in the energy storage system. The negative terminal can be electrically connected to the negative terminal of a DC power source or a DC load. The neutral terminal can be connected to the neutral point in the energy storage system, that is, the neutral terminal can be grounded.

[0045] Multiple capacitors 12 can be located on one side of the busbar 11, that is, the Z+ side in the figure. Multiple capacitors 12 can be carried by the busbar 11, that is, multiple capacitors 12 can be installed on the busbar 11 and electrically connected to the busbar 11. For example, multiple capacitors 12 can help maintain voltage stability when the operating current fluctuates, reduce the impact of current on voltage, and avoid faults such as overvoltage or undervoltage. For another example, multiple capacitors 12 can filter out noise and interference signals, achieve current smoothing, and improve operating stability and performance.

[0046] The plurality of phase units 13 may be located on the other side of the busbar 11, ie, the Z-side in the figure. Figure 4 As shown, each phase unit 13 may include a first device component 131, a second device group 132, and a third device group 133. Figure 2First device assembly 131 can be electrically connected to busbar 13 via first busbar 15a, second device group 132 can be electrically connected to busbar 11 via second busbar 15b, first device group 131 can be electrically connected to third device group 133 via third busbar 15c, second device group 132 can be electrically connected to third device group 133 via fourth busbar 15d, and third device group 133 can be electrically connected to one AC terminal 14. Phase unit 13 can be electrically connected to one of the three AC phases of an AC power source or AC load in the energy storage system via AC terminal 14.

[0047] like Figure 4 As shown, each device group in the first device assembly 131, the second device group 132, and the third device group 133 may include multiple devices 130 connected in parallel. The multiple devices 130 may be arranged along the direction indicated by the arrows X+ / X- in the figure, i.e., the first direction. As an example, the device 130 may be an IGBT device. It will be understood that the IGBT device mentioned herein may be the same as the previous IGBT device. For the purpose of brevity, the structure and operating principle of the IGBT device will not be described in detail herein. It will be understood that although each device group in the figure includes four devices 130, in other embodiments of the present invention, each device group may include other numbers of devices 130. For example, in some examples, each device group may include two, three, five, or more devices 130.

[0048] The power module 10 may include three phase units. Figure 5 As shown, first device assembly 131a, second device group 132a, and third device group 133a constitute a phase unit, hereinafter referred to as a first phase unit. First device assembly 131b, second device group 132b, and third device group 133b constitute a phase unit, hereinafter referred to as a second phase unit. First device assembly 131c, second device group 132c, and third device group 133c constitute a phase unit, hereinafter referred to as a third phase unit.

[0049] The three phase units are electrically connected to the three AC phases of the AC power source or AC load in the energy storage system. For example, the first phase unit can be electrically connected to the U phase of the AC power source or AC load via AC terminal 14a, the second phase unit can be electrically connected to the V phase of the AC power source or AC load via AC terminal 14b, and the third phase unit can be electrically connected to the W phase of the AC power source or AC load via AC terminal 14c.

[0050] Gate plate 16 can also be called a driver plate. Each device group in first device assembly 131, second device group 132, and third device group 133 can be controlled by a corresponding gate plate 16. During operation of power module 10, gate plate 16 converts control signals into drive signals. The drive signals act on the gates of the device groups to control the on and off of the device groups, thereby achieving power conversion from DC to AC or vice versa.

[0051] During operation, the phase unit 13 generates heat. To prevent overheating, the phase unit 13 is mounted on a heat sink 17. As a non-limiting example, the heat sink 17 can be implemented as a liquid cooling plate, which may have flow paths for coolant to flow through, thereby removing heat through the flowing coolant. Of course, other types of heat sinks 17 are also contemplated, such as air-cooled heat sinks with fins or gas-liquid phase change heat sinks.

[0052] The power module 10 may include two heat sinks 17, namely a first heat sink 17a and a second heat sink 17b. The length directions of the two heat sinks 17 may be consistent, and their length directions are indicated by arrows X+ / X- in the figure. The first phase unit, the second phase unit, and the third phase unit mentioned above may be arranged in sequence along the length direction of the heat sink 17. For each phase unit, as shown in FIG. Figure 5 As shown, the first device group 131 and the second device group 132 can be respectively mounted on opposite sides of the first heat dissipation plate 17 a in the thickness direction, and the third device group 133 can be respectively mounted on one side of the third heat dissipation plate 17 .

[0053] In previous power modules, the connection between the busbar and the busbar required the use of connecting posts, such as copper posts, placed between the busbar and the busbar. This is because the space on the side of the busbar facing away from the phase unit is occupied by capacitors, making it difficult for fasteners to pass through the busbar and the busbar to connect them. Connecting posts are required to achieve this. The presence of connecting posts increases the length of the line from the busbar to the phase unit, thereby increasing stray inductance and degrading performance.

[0054] To solve this problem, refer to Figure 2 and Figure 3 In the power module 10 provided in the embodiment of the utility model, a plurality of capacitors 12 can be arranged at intervals, and the busbar 11 can be provided with a transfer portion 111. For ease of understanding, Figure 3In the figure, the transition portion 111 is shown by an oblate dotted frame. On the orthographic projection of the plane where the busbar 11 is located, multiple capacitors 12 and the transition portion 111 can be arranged at intervals. The line bus 15 can be connected to the transition portion 111. That is, the busbar 11 has a transition portion 111 located between the multiple capacitors 12 and not occupied by the multiple capacitors 12, and the line bus 15 is connected to it. In this way, the connection between the line bus 15 and the busbar 11 will not require the help of a connecting column, which helps to shorten the line between the busbar 11 and the phase unit 13, thereby reducing stray inductance.

[0055] The embodiment of the present invention does not impose any particular limitation on the distribution of the capacitors 12 on the busbar 11 , as long as unoccupied transition portions 111 capable of connecting to the busbar 15 are formed between the plurality of capacitors 12 .

[0056] As an implementation method, refer to Figure 2 and Figure 3 , multiple capacitors 12 can form at least two columns of capacitor groups arranged at intervals. For ease of understanding, each column of capacitor groups is connected in series by a dot-dashed line to schematically represent their grouping relationship. Figure 3 Each column of capacitor groups can include multiple capacitors 12 arranged and extending along a first direction, that is, the X+ / X- direction in the figure. The transfer portion 111 can be located between any two adjacent columns of capacitor groups. According to this structure, the distribution of multiple capacitors 12 on the busbar 11 is more orderly, which contributes to the balanced distribution of current. In addition, according to this structure, the arrangement of multiple capacitors 12 is more compact, and the space utilization on the busbar 11 is higher, which helps to reduce the size of the busbar 11 and reduce the space occupied by the entire power module 11.

[0057] It should be noted that although Figure 3 In the example shown, each column of capacitor groups is composed of a plurality of capacitors 12 arranged in a row, and the row is neatly arranged along the first direction. However, in other examples of the present disclosure, the plurality of capacitors 12 in each column of capacitor groups can also be arranged in other ways. For example, each column of capacitor groups can also be composed of at least two rows, and the plurality of capacitors 12 in each row can be neatly arranged along the first direction, or can be arranged in a zigzag manner. Regardless of the arrangement method, as long as each column of capacitor groups as a whole presents a long strip extending along the first direction, it can be sufficient.

[0058] Further, continue to refer to Figure 2 and Figure 3 , the multiple phase units 13 can also be arranged along the first direction. That is, the multiple phase units 13 are arranged along the X+ / X- direction, and each column of capacitor groups is also arranged along the X+ / X- direction. This configuration facilitates a compact arrangement of the multiple capacitors 12 and the multiple phase units 13 in the first direction, thereby helping to reduce the size of the power module 10 in the first direction.

[0059] Further, continue to refer to Figure 2 and Figure 3 Two transition sections 111 are formed between the three capacitor groups, namely, a first transition section 111a and a second transition section 111b. A first busbar 15a can connect the first component group 131 to the first transition section 111a, and a second busbar 15b can connect the second component group 132 to the second transition section 111b, thereby electrically connecting the first and second component groups 131, 132 to the busbar 11.

[0060] It should be noted that the arrangement of the plurality of capacitors 12 on the busbar 11 is not limited to the above example. For example, in an alternative example, the arrangement extension direction of each column of capacitor groups can be parallel to the Y+ / Y- direction. For another example, in another alternative example, the plurality of capacitors 12 can be not grouped, they can be randomly distributed on the busbar 11, or they can be dispersedly arranged on the busbar 11 in an array.

[0061] The angle between the first heat sink 17a and the busbar 11 is also critical, as it affects the stray inductance in the circuit. Figure 1 and Figure 2 The first heat sink 17a and the busbar 11 can be arranged vertically, which helps shorten the lines from the first component group 131 and the second component group 132 to the busbar 11 and helps reduce the length difference between the two lines, thereby reducing stray inductance.

[0062] It should be noted that the terms "parallel" and "perpendicular" mentioned herein should be understood as "substantially parallel" and "substantially perpendicular," respectively, and a reasonable error range should be included. For example, the error range may be ±10°.

[0063] refer to Figure 2Each of the first busbar 15a and the second busbar 15b may include a first connection portion 151 and a second connection portion 152. The first connection portion 151 may be parallel to the busbar 111, and the second connection portion 151 may be parallel to the first heat sink 17a. The first connection portion 151 of the first busbar 15a may be connected to the first adapter portion 111a and extend toward a side away from the first heat sink 17a (i.e., the Y+ side in the figure). The second connection portion 152 of the first busbar 15a may be connected to the first device group 131. The first connection portion 151 of the second busbar 15b may be connected to the second adapter portion 111b and extend toward a side away from the first heat sink 17a (i.e., the Y- side in the figure). The second connection portion 152 of the second busbar 15b may be connected to the second device group 132. With this configuration, the first and second busbars 15a and 15b have fewer bends, resulting in shorter paths from the first and second component groups 131 and 132 to the busbar 11. The difference between the two paths is also smaller, resulting in lower stray inductance. Furthermore, with this configuration, the first heat sink 17a does not block the first bent portion 151, making it easier to connect the first bent portion 151 to the busbar 11.

[0064] Continue to refer Figure 2 The first connection portion 151 can be arranged in a stacked manner with the adapter portion 111, and the orthographic projection of the first connection portion 151 on the busbar 11 can at least partially overlap with the adapter portion 111. In addition, the power module 10 can further include a fastener 181 (such as a bolt, a rivet, or a screw), which can pass through the first connection portion 151 and the adapter portion 111 to connect the first connection portion 151 to the adapter portion 111. Since the adapter portion 111 is located between the capacitors 12, there is space on the side of the adapter portion 111 facing away from the line bus 15 for placing and operating the fastener 181, so that the fastener 181 can directly connect the line bus 15 and the busbar 11 together, which shortens the line between the busbar 11 and the first and second device groups 131 and 132, thereby reducing stray inductance.

[0065] refer to Figure 6The busbar 111 may include a first electrode plate 112, a second electrode plate 113, and a third electrode plate 114 arranged in a stacked manner. The first electrode plate 112, the second electrode plate 113, and the third electrode plate 114 may be arranged in sequence along a direction away from the busbar 15, that is, the Z+ direction in the figure. One of the three electrodes 112, 113, and 114 provides a positive terminal, one provides a negative terminal, and the other provides a neutral terminal. By way of example only, the first electrode plate 112 may be a positive electrode plate to provide a positive terminal, the second electrode plate 113 may be a neutral electrode plate to provide a neutral terminal, and the third electrode plate 114 may be a negative electrode plate to provide a negative terminal. By way of example only, the busbar 111 may also include two insulating layers 115, one of which is located between the first electrode plate 112 and the second electrode plate 113, and the other insulating layer 115 is located between the second electrode plate 113 and the third electrode plate 114.

[0066] The first busbar 15a can be used to electrically connect the first device group 131 with the first plate 112 and the second plate 113 of the busbar 11. Specifically, the first busbar 15a can include two stacked sub-busbars, one of which is used to electrically connect the first device group 131 with the first plate 112, and the other of which is used to electrically connect the first device group 131 with the second plate 113. These two sub-busbars can each include a first plate portion 153 and a second plate portion 154. The first plate portion 153 and the second plate portion 154 are stacked and arranged in sequence, facing away from the busbar 11 (i.e., the Z-direction in the figure). The two plate portions 153 and 154 can collectively constitute the first connection portion 151 of the first busbar 15a.

[0067] The second busbar 15b can be used to electrically connect the second component group 131 with the second plate 113 and the third plate 114 of the busbar 11. Specifically, the second busbar 15b can also include two stacked sub-busbars, one of which is used to electrically connect the second component group 132 with the second plate 113, and the other of which is used to electrically connect the second component group 132 with the third plate 114. These two sub-busbars also include a first plate portion 153 and a second plate portion 154, respectively. The first plate portion 153 and the second plate portion 154 are stacked and arranged in sequence along a direction away from the busbar 11, i.e., the Z-direction in the figure. The two plate portions 153 and 154 can together constitute the first connection portion 151 of the second busbar 15b.

[0068] In both the first wiring array 15a and the second wiring array 15b, the two plate portions 153 and 154 can be connected to the three electrode plates 112, 113, and 114 via the first connecting structure 191 and / or the second connecting structure 192. For example, any plate portion can be connected to the electrode plates via the first connecting structure 191. In another example, any plate portion can be connected to the electrode plates via the second connecting structure 192. In another example, one plate portion can be connected to one electrode plate via the first connecting structure 191, while another plate portion can be connected to another electrode plate via the second connecting structure 192.

[0069] The first connection structure 191 can be a bending structure, which is composed of a connected plate portion and a pole plate. Specifically, the plate portion and the pole plate can be bent toward each other through an integrated stamping process to form the first connection structure 191. The first connection structure 191 has the advantages of a large flow area and low internal impedance, but it needs to occupy a larger area on the busbar 11. The second connection structure 192 can be a boss structure, which can be composed of a connected plate portion and a pole plate, or it can be composed of one of the plate portion and the pole plate. Specifically, one or both of the plate portion and the pole plate can be provided with a boss extending toward each other to form the second connection structure 192. The second connection structure 192 has the advantage of a compact structure, and it occupies a smaller area on the busbar 11.

[0070] Next, the connection structure between the first wiring array 15 a and the first transition portion 111 a is described with an example.

[0071] refer to Figure 3 and Figure 7 For the first wiring array 15a, the first plate portion 153 and the second electrode plate 113 can be connected via a first connection structure 191. Specifically, the first plate portion 153 can have a bent portion 1531 that bends toward the second electrode plate 113, and the second electrode plate 113 can have a bent portion 1131 that bends toward the first plate portion 153. The bent portion 1531 and the bent portion 1131 can together constitute the first connection structure 191. The first electrode plate 112 can have an avoidance hole 1121. The avoidance hole 1121 can avoid the first connection structure 191. The fastener 181 can pass through the bent portion 1531 and the bent portion 1131 to connect the two together.

[0072] refer to Figure 3 and Figure 8For the first wiring array 15a, the second plate portion 154 and the first electrode plate 112 can be connected via a second connection structure 192. Specifically, the second plate portion 154 can have a boss 1541 extending toward the second electrode plate 113. The boss 1541 can independently constitute the second connection structure 192. The first plate portion 153 can have an escape hole 1532. The escape hole 1532 can avoid the second connection structure 192, that is, avoid the boss 1541. The fastener 181 can pass through the boss 1541 and the first electrode plate 112 to connect them together.

[0073] like Figure 3 As shown, the first busbar 15a and the first transition portion 111a can form a plurality of first connection structures 191 and a plurality of second connection structures 192. The plurality of first connection structures 191 and the plurality of second connection structures 192 can be arranged alternately and spaced apart from each other. This can take advantage of the large flow area of the first connection structures 191 and the small footprint of the second connection structures 192 to ensure a sufficiently large flow area while simultaneously ensuring a compact arrangement of the first and second connection structures 191, 192, thereby reducing the size of the power module 10.

[0074] Next, the connection structure between the second wiring array 15 b and the second transition portion 111 b is described with an example.

[0075] Reference again Figure 3 and Figure 8 For the second wiring bus 15b, the first plate portion 153 and the second electrode plate 113 can be connected via a first connection structure 191. Specifically, the first plate portion 153 can have a bent portion 1531 that bends toward the second electrode plate 113, and the second electrode plate 113 can have a bent portion 1131 that bends toward the first plate portion 153. The bent portion 1531 and the bent portion 1131 can together constitute the first connection structure 191. The first electrode plate 112 can have an avoidance hole 1121. The avoidance hole 1121 can avoid the first connection structure 191. The fastener 181 can pass through the bent portion 1531 and the bent portion 1131 to connect the two together.

[0076] Reference again Figure 3 and Figure 7For the second busbar 15b, the second plate portion 154 and the third electrode plate 114 can be connected via a second connection structure 192. Specifically, the second plate portion 154 can have a boss 1541 extending toward the third electrode plate 114, and the third electrode plate 114 can have a boss 1141 extending toward the second plate portion 154. Boss 1541 and boss 1141 can together constitute the second connection structure 192. The first plate portion 153 can be provided with an avoidance hole 1532, the first electrode plate 112 can be provided with an avoidance hole 1121, and the second electrode plate 113 can be provided with an avoidance hole 1132. Avoidance holes 1532, 1121, and 1132 can avoid the second connection structure 192, that is, avoid boss 1541 and boss 1141. Fasteners 181 can pass through boss 1541 and boss 1141 to connect them together.

[0077] like Figure 3 As shown, the second busbar 15b and the second transition portion 111b can also form multiple first connection structures 191 and multiple second connection structures 192. The multiple first connection structures 191 and the multiple second connection structures 192 can be arranged alternately and spaced apart from each other. This can take advantage of the large flow area of the first connection structures 191 and the small footprint of the second connection structures 192 to ensure a sufficiently large flow area while simultaneously ensuring a compact arrangement of the first and second connection structures 191, 192, thereby reducing the size of the power module 10.

[0078] Continue to refer Figure 3 , a plurality of transition portions 111 may be provided between two adjacent columns of capacitor groups, and the plurality of transition portions 111 may be sequentially spaced and arranged along the first direction to form a plurality of gap regions 110. In other words, for the plurality of transition portions 111 between two adjacent columns of capacitor groups, a gap region 110 is provided between two adjacent transition portions 111. For ease of understanding, Figure 3 In the figure, the gap area 110 is schematically illustrated by a rectangular dashed box. In the orthographic projection of the plane on which the busbar 11 lies, part of the capacitor 12 can be located within the gap area 110. Considering that the capacitor 12 is roughly cylindrical, through this arrangement of the transition portion 111 and the gap area 110, the narrowest part of the circular outer contour of the capacitor 12 can be aligned with the gap area 110, achieving the staggered arrangement of the capacitor 12 and the transition portion 111, thereby further improving the space utilization on the busbar 11 and further reducing the size.

[0079] Continue to refer Figure 3 The transition portion 111 has a width W, which is the width of the transition portion 111 in the second direction, ie, the Y+ / Y- direction. In this document, the first direction, the second direction, and the third direction (ie, the Z+ / Z- direction) are perpendicular to each other.

[0080] The width W of the transition portion 111 may satisfy: 12 mm ≤ W ≤ 100 mm.

[0081] Considering the need to meet safe electrical clearance requirements, width W should not be too small. However, if width W is too large, it will occupy too much space on busbar 11, hindering the reduction of the overall size of power module 10. Setting width W to 12 mm ≤ W ≤ 100 mm can address both of these requirements, meeting safe electrical clearance requirements without significantly increasing space usage.

[0082] Preferably, the width W of the transition portion 111 may satisfy: 18 mm ≤ W ≤ 30 mm.

[0083] In addition to meeting safe electrical clearance requirements, consideration must also be given to the operating space for installation tools, such as screwdrivers, and the flow area between the wire bus 15 and the adapter 111. Setting the width W to 18mm≤W≤30mm allows for adequate space for installation tools, provides a sufficient flow connection between the bus 15 and the adapter 111, and further reduces space usage.

[0084] Alternatively, the width W of the transition portion 111 may be any value among 20 mm, 22 mm, 24 mm, 26 mm, and 28 mm.

[0085] Not only the capacitors 12 on both sides of the transition portion 111 need to meet the safety electrical clearance requirements, but any two adjacent capacitors 12 also need to meet the safety electrical clearance requirements. For example, in a column of capacitors, adjacent capacitors 12 also need to meet the safety electrical clearance requirements.

[0086] In view of this, in some examples, any two adjacent capacitors 12 have a distance D, and the distance D may satisfy: D ≥ 5 mm.

[0087] Thus, this can ensure the reliability and safety of the power module 10 .

[0088] Preferably, the distance D may satisfy: 6 mm ≥ D ≥ 8 mm.

[0089] In this way, reliability and safety can be ensured without significantly increasing the space occupied by the multiple capacitors 12.

[0090] The present invention also provides a power module 10a. Figures 9 to 15 The power module 10a described below has many of the same elements as the power module 10 described above. For the purpose of brevity, these same elements will be denoted by the same reference numerals in the text to omit repeated descriptions as appropriate.

[0091] First reference Figures 9 to 11The power module 10a may include two busbars 11, two first heat sinks 17a, one second heat sink 17b, and six phase units. The six phase units may include the two first phase units, two second phase units, and two third phase units described above. Each busbar 11 carries multiple capacitors 12 and is electrically connected to the first, second, and third phase units. A first component group 131 and a second component group 132 are provided on opposite sides of each first heat sink 17a, while a third component group 133 is provided on opposite sides of each second heat sink 17b. The first component group 131 and the second component group 132 on each first heat sink 17a can be electrically connected to the corresponding busbar 11 via first and second busbars 15a and 15b, respectively, and can be electrically connected to the third component group 133 located on one side of the second heat sink 17b via third and fourth busbars 15c and 15d. The connection methods can be referred to in the above embodiments and will not be further described here. Thus, the power module 10a has six phase units, which increases the operating efficiency of the power module 10a.

[0092] like Figure 10 As shown, in the thickness direction of the second heat sink 17b, the two first heat sinks 17a can be located on opposite sides of the second heat sink 17b. In the width direction of the second heat sink 17b, the two first heat sinks 17a can be located on the same side of the second heat sink 17b. The two first heat sinks 17a can be arranged at an angle so that the distance between them gradually increases as they move away from the second heat sink 17b. In this arrangement, Figure 10 When viewed from the perspective of FIG, the three heat dissipation plates 17 are roughly Y-shaped.

[0093] This arrangement helps shorten the lines from the first and second device groups 131 and 132 to the corresponding third device group 133 on each heat sink 17, and ensures that the difference in line length between the first and second device groups 131 and 132 and the corresponding third device group 133 is small. Shorter lines and a smaller difference in line length help reduce stray inductance.

[0094] The two busbars 11 can be electrically connected and arranged at an angle. In this way, the two busbars 11 can each have a suitable angle relative to the two first heat sinks 17a, for example, perpendicular to each other. This helps ensure that, for either of the two first heat sinks 17a, the line from the first component group 131 thereon to the corresponding busbar 11 and the line from the second component group 132 thereon to the corresponding busbar 11 are both short, with the difference in length between the two lines being small. Shorter lines and a smaller difference in line length help reduce stray inductance.

[0095] There are many ways to electrically connect the two busbars 11, and the present invention does not impose any particular restrictions on this. For example, the two busbars 11 can be directly connected together. For another example, the two busbars 11 can be electrically connected through an intermediary.

[0096] As an exemplary implementation, refer to Figure 11 and Figure 14 The edge of each busbar 11 close to the other busbar 11 may be provided with a lug portion 116 protruding toward the other busbar 11. The lug portions 116 of the two busbars 11 are connected to achieve electrical and physical connection of the two busbars 11.

[0097] There are many ways to connect the two lugs 116 of the two busbars 11, which are not particularly limited in the present embodiment. For example, the two lugs 116 can be connected together using fasteners. In another example, the two lugs 116 can be connected together by welding, bonding, riveting, etc.

[0098] As an exemplary implementation, refer to Figure 11 、 Figure 14 and Figure 15 The two lugs 116 of the two busbars 11 can be stacked, that is, one lug 116 can be placed on top of another lug 116. The power module 10a can also include fasteners 182 (such as bolts or screws) that pass through the two lugs 116 to fasten and connect them together. This approach offers advantages such as reliable connection, simple structure, and easy assembly and disassembly.

[0099] By way of example only, the two lug portions 116 of the two busbars 11 may be fastened by two fasteners 182, and the two fasteners 182 may be spaced apart. It is understood that in other examples, the two lug portions 116 may be fastened by only one fastener 182, or the two lug portions 116 may be fastened by three or more fasteners 182.

[0100] Continue to refer Figure 11 、 Figure 14 and Figure 15Each busbar 11 may be provided with a plurality of lugs 116, which may include a first lug 116a and a second lug 116b. The first lug 116a may be provided by the first electrode plate 112, that is, the first lug 116a may be a part of the first electrode plate 112, or may be connected to the first electrode plate 112. The second lug 116b may be provided by the third electrode plate 114, that is, the second lug 116b may be a part of the third electrode plate 114, or may be connected to the third electrode plate 114. The first lug 116a of one busbar 11 is connected to the first lug 116a of another busbar 11, and the second lug 116b of one busbar 11 is connected to the second lug 116b of another busbar 11. In this way, the first electrode plates 112 and the third electrode plates 114 of the two busbars 11 are electrically connected, and at the same time, the two busbars 11 are physically connected together.

[0101] Further, continue to refer to 11, Figure 14 and Figure 15 Each busbar 11 can have multiple first lugs 116a and multiple second lugs 116b. These lugs 116a and 116b can be arranged alternately, and any adjacent first lugs 116a and second lugs 116b can be spaced apart. This improves the physical connection strength between the two busbars 11, improves the balanced current distribution, and ensures insulation between the first and third plates 112 and 114.

[0102] The present invention further provides a power conversion device which may include the above-mentioned power module.

[0103] According to an embodiment of the present invention, a power conversion device 100 is provided. Figure 16 As shown in Figure 16 As shown, the power conversion device 100 may include a cabinet 20 and a DC fuse 30, a DC disconnect switch 40, the power module 10 provided in the aforementioned aspects, a reactor 50, an AC filter capacitor 60 and an AC circuit breaker 70 housed in the cabinet 20 and electrically connected in sequence.

[0104] According to an embodiment of the present invention, a power conversion device 100a is provided. Figure 17 As shown in Figure 17As shown, the power conversion device 100a may include a cabinet 20, and a DC fuse 30, a DC disconnect switch 40, the power module 10a provided in the aforementioned aspects, two reactors 50, an AC filter capacitor 60, and an AC circuit breaker 70, which are housed in the cabinet 20 and electrically connected in sequence. One of the two reactors 50 can be electrically connected to the AC terminals 14a, 14b, and 14c of three phase units, and the other can be electrically connected to the AC terminals 14a, 14b, and 14c of the other three phase units.

[0105] It should be understood that the term "including" and its variations used in the embodiments of the present invention are open-ended, i.e., "including but not limited to." The term "according to" means "at least in part according to." The term "one embodiment" means "at least one embodiment," and the term "another embodiment" means "at least another embodiment."

[0106] It should be understood that although the terms "first" or "second" may be used in embodiments of the present invention to describe various elements, such as a first heat sink and a second heat sink, these elements are not defined by these terms, which are only used to distinguish one element from another.

[0107] The scope of protection of the present invention is not limited to the above-mentioned embodiments. Any changes or substitutions that can be conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A power module, characterized in that: include: busbar; a plurality of capacitors, disposed on one side of the busbar and electrically connected to the busbar; a plurality of phase units, arranged on the other side of the busbar; as well as A busbar electrically connects the plurality of phase units to the busbar, The plurality of capacitors are arranged at intervals, the busbar is provided with a transition portion, and on the orthographic projection of the plane where the busbar is located, the plurality of capacitors and the transition portion are arranged at intervals, and the busbar is connected to the transition portion.

2. The power module according to claim 1, wherein: The plurality of capacitors form at least two columns of capacitor groups arranged at intervals. The capacitor group includes a plurality of capacitors arranged and extending along a first direction. The transition portion is located between any two adjacent columns of the capacitor groups.

3. The power module according to claim 2, wherein: The plurality of phase units are arranged along the first direction.

4. The power module according to claim 3, wherein: The present invention comprises two wire rows, the two wire rows comprise a first wire row and a second wire row, each phase unit comprises a first device group and a second device group, two transition portions spaced apart from each other are formed between the three columns of the capacitor groups, the two transition portions comprise a first transition portion and a second transition portion, the first wire row electrically connects the first device group to the first transition portion, and the second wire row electrically connects the second device group to the second transition portion.

5. The power module according to claim 4, characterized in that: It also includes a heat dissipation plate, and the first component group and the second component group are respectively arranged on two opposite sides of the heat dissipation plate in the thickness direction.

6. The power module according to claim 5, characterized in that: The heat dissipation plate and the busbar are arranged perpendicular to each other.

7. The power module according to claim 6, characterized in that: Each of the first and second busbars includes a first connection portion parallel to the busbar and a second connection portion parallel to the heat sink; the first connection portion of the first busbar is connected to the first adapter portion and extends toward a side away from the heat sink; the second connection portion of the first busbar is connected to the first component group; the first connection portion of the second busbar is connected to the second adapter portion and extends toward a side away from the heat sink; and the second connection portion of the second busbar is connected to the second component group.

8. The power module according to claim 1, wherein: The busbar includes a first connecting portion, the first connecting portion and the transition portion are stacked, and an orthographic projection of the first connecting portion on the busbar at least partially overlaps with the transition portion; The power module further includes a fastener passing through the first connecting portion and the transition portion to connect the first connecting portion with the transition portion.

9. The power module according to claim 8, characterized in that: The first connecting portion includes a first plate portion and a second plate portion stacked in sequence along a direction away from the busbar, and the busbar includes a first electrode plate, a second electrode plate, and a third electrode plate stacked in sequence along a direction away from the line bar, wherein: The first plate portion and the second electrode plate are connected via a first connecting structure, the first electrode plate is provided with an avoidance hole for avoiding the first connecting structure, the first connecting structure comprises two bent portions of the first plate portion and the second electrode plate bent toward each other, the fastener passes through the two bent portions to connect the two; and / or, The second plate portion is connected to the first electrode plate through a second connecting structure. The first plate portion is provided with an avoidance hole for avoiding the second connecting structure. The second connecting structure includes a boss of the second plate portion extending toward the first electrode plate. The fastener passes through the boss and the first electrode plate to connect the two.

10. The power module according to claim 8, characterized in that: The first connecting portion includes a first plate portion and a second plate portion stacked in sequence along a direction away from the busbar, and the busbar includes a first electrode plate, a second electrode plate, and a third electrode plate stacked in sequence along a direction away from the line bar, wherein: The first plate portion and the second electrode plate are connected via a first connecting structure, the first electrode plate is provided with an avoidance hole for avoiding the first connecting structure, the first connecting structure comprises two bent portions of the first plate portion and the second electrode plate bent toward each other, the fastener passes through the two bent portions to connect the two; and / or, The second plate portion is connected to the third electrode plate through a second connecting structure. The first plate portion, the first electrode plate and the second electrode plate are all provided with avoidance holes for avoiding the second connecting structure. The second connecting structure includes two bosses extending toward each other of the second plate portion and the third electrode plate. The fastener passes through the two bosses to connect the two.

11. The power module according to claim 9 or 10, characterized in that: The plurality of first connection structures and the plurality of second connection structures are alternately arranged and spaced apart from each other.

12. The power module according to claim 9 or 10, characterized in that: The first electrode plate is a positive electrode plate, the second electrode plate is a neutral electrode plate, and the third electrode plate is a negative electrode plate.

13. The power module according to claim 2, wherein: A plurality of transition portions are provided between two adjacent columns of the capacitor groups, and the plurality of transition portions are sequentially spaced apart along the first direction to form a gap area; In the orthographic projection of the plane where the busbar is located, part of the capacitor is located in the gap area.

14. The power module according to claim 1, wherein: The transition portion has a width W, and the width W satisfies: 12 mm ≤ W ≤ 100 mm.

15. The power module according to claim 1, wherein: Any two adjacent capacitors have a distance D, and the distance D satisfies: D≥5mm.

16. The rate module according to claim 1, characterized in that Each phase unit includes a first component group, a second component group, and a third component group. The first component group and the second component group are electrically connected to the busbar and the third component group. The third component group is electrically connected to the AC phase.

17. The power module according to claim 16, characterized in that: The first device group, the second device group, and the third device group are all IGBT device groups, and each IGBT device group includes a plurality of IGBT devices connected in parallel.

18. A power conversion device, characterized in that: The invention comprises a cabinet body and a DC fuse, a DC isolating switch, a power module, a reactor, an AC filter capacitor and an AC circuit breaker which are housed in the cabinet body and electrically connected in sequence. The power module is the power module according to any one of claims 1 to 17.

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