Coil modules and power converters

Abstract

In the coil module, the coil device includes: a coil unit; and at least one terminal extending from the coil unit. The housing is configured to accommodate the coil device. At least one busbar is fixed to the housing. At least one terminal is electrically connected to the at least one busbar. The potting member is filled in the housing to firmly hold the coil device in the housing.

Description

Technical Field

[0001] The present invention relates to a coil module and a power converter including such a coil module. Background Art

[0002] A power converter such as an inverter for a vehicle is equipped with a coil device that serves as a noise filter for removing electrical noise. Japanese Patent Application Publication No. 2012-156496 discloses a power converter including a circuit board on which a switching element and a coil device having terminals are mounted. Specifically, the power converter described in the above patent publication is configured so that the terminals of the coil device are directly mounted on the circuit board, thereby enabling the coil device to be directly mounted on the circuit board. Summary of the invention

[0003] Recent strict electromagnetic compatibility (EMC) specifications or standards require coil devices to have larger sizes. Each power converter includes such a large coil device directly mounted on a circuit board, which results in a smaller mounting area on the circuit board. Therefore, each power converter including a coil device requires the coil device to have a higher degree of flexibility in arrangement.

[0004] To meet such requirements, the present disclosure seeks to provide a coil module, each of which enables a higher degree of flexibility in arrangement of coil arrangements, and also provides a power converter, each of which includes at least one of the coil modules.

[0005] According to a first exemplary aspect of the present disclosure, a coil module is provided. The coil module includes a coil device and a housing configured to accommodate the coil device, wherein the coil device has a coil unit and at least one terminal extending from the coil unit. The coil module includes: at least one bus bar, at least one bus bar is fixed to the housing; at least one terminal, at least one terminal is electrically connected to at least one bus bar; and a potting member, the potting member is filled in the housing to firmly hold the coil device in the housing.

[0006] According to a second exemplary aspect of the present disclosure, a power converter is provided. The power converter includes: a coil module as defined in the first exemplary aspect; and a circuit board, the circuit board having at least one switch for power conversion mounted thereon. The coil device of the coil module is electrically connected to the circuit board via at least one busbar.

[0007] The coil module according to the first exemplary aspect includes: a coil device; a housing configured to accommodate the coil device; and at least one bus bar fixed to the housing. At least one terminal extending from a coil unit of the coil device is electrically connected to the at least one bus bar.

[0008] This configuration of the coil module enables the coil device to be electrically connected to the circuit board via at least one busbar. Therefore, this allows the coil device to have a higher degree of flexibility in arrangement. That is, this configuration of the coil module improves the degree of arrangement flexibility of the coil device in the device using the coil module.

[0009] In the power converter according to the second exemplary aspect, the coil device of the coil module is electrically connected to the circuit board via at least one busbar. Therefore, this allows the coil device to have a higher degree of flexibility in arrangement. That is, this configuration of the power converter improves the degree of arrangement flexibility of the coil device in the power converter. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Other aspects of the present disclosure will become apparent from the following description of embodiments with reference to the accompanying drawings, in which:

[0011] Figure 1 is a perspective view of a coil module according to a first embodiment of the present disclosure;

[0012] Figure 2 yes Figure 1 A plan view of the coil module shown;

[0013] Figure 3 yes Figure 2 The coil housing shown is along Figure 2 A sectional view taken along line III-III of FIG. 1 and observed from the direction of arrow III-III;

[0014] Figure 4 The coil housing is along Figure 2 A sectional view taken along line IV-IV of FIG. 1 and observed from the direction of arrow IV-IV;

[0015] Figure 5 is an enlarged perspective view of the coil assembly according to the first embodiment;

[0016] Figure 6 is an enlarged stereoscopic view of the connection portion between the connection terminal and the coil terminal;

[0017] Figure 7 is a circuit diagram schematically showing a power converter according to a first embodiment;

[0018] Figure 8 is a partial cross-sectional plan view of a portion of a power converter;

[0019] Fig. 9 It is along Figure 8 A sectional view taken along the line IX-IX of FIG. 1 and observed from the direction of arrow IX-IX;

[0020] Fig.10 It is along Figure 8 A cross-sectional view taken along line XX and viewed from the direction of arrow XX;

[0021] Fig.11 is an enlarged perspective view of a connection portion between a connection terminal and a coil terminal according to a second embodiment of the present disclosure;

[0022] Fig.12 A modification of the second embodiment is different from the first embodiment. Figure 3 a cross-sectional view of the corresponding coil module;

[0023] Fig.13 is a partial cross-sectional plan view of a power converter according to a third embodiment of the present invention; and

[0024] Fig.14 It is along Fig.13 A sectional view taken along line XIV-XIV and viewed from the direction of arrows XIV-XIV. DETAILED DESCRIPTION

[0025] Hereinafter, a coil module as an embodiment of the present disclosure will be described with reference to the accompanying drawings. In each embodiment, similar or equivalent parts assigned with the same reference numerals between the embodiments are omitted or simplified to avoid redundant description.

[0026] First embodiment

[0027] Below, reference Figures 1 to 10 The coil module 1 and the power converter including the coil module 1 are described.

[0028] refer to Figures 1 to 4 The coil module includes a coil device 2, a coil housing 3, a busbar 4 and a potting component 5.

[0029] The coil device 2 includes a coil assembly 21 serving as a coil unit, and the coil housing 3 is configured to accommodate the coil device 2. The busbar 4 is fixed to the coil housing 3. The potting member 5 is filled in the coil housing 3 to firmly hold the coil device 2 in the coil housing 3 and protect the coil device 2 from various environments. The coil device 2 includes a terminal 22 extending from the coil assembly 21, which is called a coil terminal. The coil terminal 22 is electrically connected to the busbar 4.

[0030] refer to Figures 1 to 4The coil housing 3 made of an electrically insulating material such as resin includes a container member 31 having a substantially rectangular parallelepiped shape. The container member 31 has an internal space inside thereof and has: a base wall 310; and a top wall 311 located at the opposite side of the base wall 310. The top wall 311 has: a peripheral edge 311a; and an opening 311b defined in the peripheral edge 311a, and therefore, the top wall 311 serves as an opening wall 311.

[0031] The coil device 2 is accommodated in the inner hollow space of the container member 31 so that the normal direction of the opening wall 311 of the container member 31 is substantially parallel to the extending direction of the coil terminals 22 of the coil device 2 .

[0032] In this specification, the normal direction of the opening wall 311 of the container member 31 perpendicular to the base wall 310 is defined as the Z direction. In other words, the Z direction is defined as a reference axis between the base wall 310 and the opening wall 311 .

[0033] The Z direction has a first direction side corresponding to the extension side of the terminal 22, which is conveniently referred to as the upper side, and also has a second direction side opposite to the first direction side, which is conveniently referred to as the lower side. The upper side and the lower side of the Z direction are only used for convenience, and therefore, the upper side and the lower side of the Z direction are not limited to the arrangement and posture of the coil module 1.

[0034] like Figure 5 As shown, the coil device 2 includes a toroidal core 23 in which a magnetic circuit is generated. The coil device 2 also includes a first winding 211 and a second winding 212, each of which is a conductive wire wound around the toroidal core 23, and the first winding 211 and the second winding 212 are electrically isolated from each other. The first winding 211 and the second winding 212 wound around the toroidal core 23 constitute the coil assembly 21.

[0035] Specifically, the first winding 211 is wound through, for example, the inside and outside of the first half of the toroidal core 23 a prescribed number of times, and similarly, the second winding 212 is wound through, for example, the inside and outside of the second half of the toroidal core 23 a prescribed number of times. The first winding 211 wound around the first half of the toroidal core 23 and the second winding 212 wound around the second half of the toroidal core 23 are magnetically coupled to each other via the core 23. That is, the coil device 2 is designed as a toroidal coil device.

[0036] Each of the first winding 211 and the second winding 212 has opposite first and second ends in the length direction thereof, and the first and second ends of the first winding 211 and the second winding 212, that is, the four ends of the first winding 211 and the second winding 212 serve as corresponding coil terminals 22. The four coil terminals 22 extend, for example, in parallel toward the first direction side in the Z direction, and the coil device 2 is installed in the container member 31.

[0037] The coil device 2 further includes a bobbin 24 made of, for example, resin. The bobbin 24 is configured to hold the coil assembly 21 and the iron core 23.

[0038] While the coil device 2 is installed in the container member 31 , the annular core 23 has opposite first and second ends, wherein the first end is positioned closer to the opening wall 311 than the base wall 310 , and the second end is positioned closer to the base wall 310 than the opening wall 311 .

[0039] The bobbin 24 includes a cover member 241, for example, in the shape of a substantially rectangular plate, and the cover member 241 is designed to be consistent with the shape of the opening wall 311 of the container member 31. The cover member 241 is configured to be adjacent to the first end of the annular core 23. The bobbin 24 also includes at least two leg members 242, each of which extends from the cover member 241 toward the second direction side of the Z direction. In other words, each leg member 242 extends from the cover member 241 in a direction opposite to the extension direction of the coil terminal 22. The annular core 23 has opposite annular surfaces in its axial direction perpendicular to the Z direction. The leg members 242 are respectively located on both sides of the annular core 23 to face the corresponding annular surfaces of the annular core 23.

[0040] The coil device 2 includes a not-shown core cover that covers the annular core 23. The core cover is, for example, fixed to the cover member 241. That is, the first winding 211 and the second winding 212 are wound around the annular core 23 through the core cover.

[0041] The container member 31 comprises a first pair of longitudinal side walls 310a, 310b and a second pair of transverse side walls 310c, 310d. These side walls 310a to 310d and the bottom wall 310 define an internal hollow space therein. The longitudinal direction of the longitudinal side walls 310a, 310b perpendicular to the Z direction is also defined as the Y direction.

[0042] The cover member 241 has opposite first and second main sides and is arranged such that the second main side of the cover member 241 faces the first end of the annular core 23 and the first main side of the cover member 241 turns to the first direction side in the Z direction.

[0043] like Figure 1 , Figure 2 and Figure 5As shown, the cover member 241 has: a first pair of opposite longitudinal edges corresponding to opposite longitudinal side walls 310a, 310b; and a second pair of opposite lateral edges corresponding to opposite lateral side walls 310c, 310d. The cover member 241 includes a notch 243 formed in the corresponding longitudinal edge, and the notch 243 is positioned to align with the corresponding coil terminal 22 in the Z direction. That is, the coil terminal 22 is arranged to extend from the coil assembly 21 toward the first direction side of the Z direction while passing through the corresponding notch 243. Each longitudinal edge of the cover member 241 extends in the Y direction perpendicular to the Z direction.

[0044] In addition, the cover member 241 includes, for example, engagement members 244 protruding outward from opposite longitudinal edges thereof. While the coil device 2 is installed in the container member 31, the coil terminal 22 is positioned to pass through the corresponding notch 243, and the engagement members 244 of the cover member 241 are respectively engaged with the corresponding portions 34 of the peripheral edge 311a of the top wall 311 of the container member 31. This enables the positioning of the coil terminal 22 and the coil assembly 2 relative to the coil housing 3 to be completed.

[0045] The busbar 4 includes: a first busbar 41 serving as a positive busbar; a second busbar 42 serving as a negative busbar; a third busbar 46 serving as a positive busbar; and a fourth busbar 47 serving as a negative busbar.

[0046] Each of the first to fourth busbars 4 (41, 42, 46, 47) is fixed to the insulating coil case 3. For example, each of the first to fourth busbars 4 (41, 42, 46, 47) is embedded in the coil case 3, and a prescribed portion of a corresponding one of the first to fourth busbars 4 (41, 42, 46, 47) is exposed from the coil case 3. For example, the resin coil case 3 is formed using insert molding, wherein a prescribed portion of each of the first to fourth busbars 4 (41, 42, 46, 47) is placed in the above-mentioned resin coil case 3.

[0047] like Figures 1 to 3 and Figure 7 As shown, each of the first busbar 41 and the second busbar 42 includes an input terminal 43 and a connection terminal 45 exposed from the coil housing 3. Figures 1 to 3 and Figure 7 As shown, each of the third bus bar 46 and the fourth bus bar 47 includes a connection terminal 45 and an output terminal 44 exposed from the coil case 3 .

[0048] The connecting terminals 45 of the corresponding first busbar 41 and the second busbar 42 are arranged to extend from the coil housing 3 to engage with the coil terminals (first ends) 22 of the corresponding first winding 211 and the second winding 212, and the connecting terminals 45 of the corresponding third busbar 46 and the fourth busbar 47 are arranged to extend from the coil housing 3 to engage with the coil terminals (second ends) of the corresponding first winding 211 and the second winding 212.

[0049] For example, the connecting terminals 45 of the corresponding first busbar 41 and the second busbar 42 are welded to the coil terminals (first ends) 22 of the corresponding first winding 211 and the second winding 212, and the connecting terminals 45 of the corresponding third busbar 46 and the fourth busbar 47 are welded to the coil terminals (second ends) of the corresponding first winding 211 and the second winding 212.

[0050] The input terminal 43 of each of the first bus bar 41 and the second bus bar 42 is connected to a DC power source BAT, that is, a battery (see FIG. Figure 7 ), and the output terminal 44 of each of the third busbar 46 and the fourth busbar 47 is connected to the circuit board 12 to be described later (see Figure 7 ).

[0051] The potting member 5 is configured together with the coil device 2 in the container member 31. For example, the potting member 5 is made of, for example, epoxy resin. The potting member 5 is filled in the lower part of the internal hollow space of the container member 31, so that the lower part of the coil device 2 is embedded in the potting member 5, and the lower part of the coil device 2, that is, the coil assembly 21 is also referred to as the embedded part hereinafter.

[0052] That is, the potting member 5 enables the coil device 2 to adhere to the container member 31 and thereby be fixed to the container member 31. The potting member 5 arranged in the lower portion of the inner hollow space of the container member 31 has a top surface 51 in the Z direction, which serves as, for example, a potting surface.

[0053] like Figure 3 and Figure 4 As shown, the coil component 21 includes an exposed portion 213 exposed from the potting member 5. That is, the coil component 21 includes: an embedded portion, the embedded portion is embedded in the potting member 5; and an exposed portion 213, the exposed portion 213 is exposed from the potting member 5. The potting member 5 allows the lower portion of the coil component 21 to be embedded in the potting member 5, while another portion of the coil component 21 is exposed from the potting member 5 as the exposed portion 213.

[0054] The exposed portion 213 of the coil component 21 has a predetermined length in the normal direction of the top surface 51 of the holding member 5 parallel to the Z direction, and the length of the exposed portion 213 is set to be equal to or greater than half of the length of the coil component 21 in the Z direction, that is, in the axial direction thereof. Figure 4 As shown, the length of the exposed portion 213 of the coil component 21 in the Z direction is d1, and the length of the embedded portion of the coil component 21 in the Z direction is d2, and the length d1 is set to be equal to or greater than the length d2. In particular, the exposed portion 213 of the coil component 21 is exposed from the potting member 5, so that the axial length d1 of the exposed portion 213 is greater than the axial length d2 of the embedded portion.

[0055] The coil housing 3 is made of resin, such as PBT (polybutylene terephthalate) resin. Each of the coil housing 3 and the potting member 5 has a given linear expansion coefficient, and in view of the reduction of cold energy stress between the coil housing 3 and the potting member 5, the linear expansion coefficient of the coil housing 3 can be preferably set to be close to the linear expansion coefficient of the potting member 5. For example, the amount of filler filled into at least one of the resin of the coil housing 3 and the resin of the potting member 5 is adjusted so that the linear expansion coefficient of the coil housing 3 is approximately equal to the linear expansion coefficient of the potting member 5.

[0056] refer to Figure 1 and Figure 2 The coil housing 3 further includes a first bus bar holder 32 and a second bus bar holder 33 as a single member, which are integrally formed with the container member 31. The first bus bar holder 32 is configured to extend continuously from the longitudinal side wall 310a of the container member 31 away from the longitudinal side wall 310a in a direction perpendicular to the Z direction and the Y direction, and this direction in which the first bus bar holder 32 extends is defined as the X direction. Similarly, the second bus bar holder 33 is configured to extend continuously from the longitudinal side wall 310b of the container member 31 away from the longitudinal side wall 310b in the X direction perpendicular to the Z direction and the Y direction.

[0057] The X direction has a first direction side corresponding to the extension direction of the first bus bar holder 32 away from the container member 31 and a second direction side corresponding to the extension direction of the second bus bar holder 33 away from the container member 31 .

[0058] In other words, the first bus bar holder 32 and the second bus bar holder 33 are located on both sides of the container member 31 in the X direction, and therefore, the first bus bar holder 32 , the container member 31 , and the second bus bar holder 33 are aligned in the X direction.

[0059] The first bus bar 41 has opposite first and second ends in its length direction. The first bus bar 41 extends from the container member 31 through the first bus bar holder 32, and the first end of the first bus bar 41 on the first direction side in the X direction is exposed from the extended end of the first bus bar holder 32 on the first direction side in the X direction. The exposed first end of the first bus bar 41 is formed as an input terminal 43 of the first bus bar 41.

[0060] Similarly, the second bus bar 42 has opposite first and second ends in its length direction. The second bus bar 42 extends from the container member 31 through the first bus bar holder 31, and the first end of the second bus bar 42 on the first direction side in the X direction is exposed from the extended end of the first bus bar holder 32 on the first direction side in the X direction. The exposed first end of the second bus bar 42 is formed as an input terminal 43 of the second bus bar 42.

[0061] The third busbar 46 has opposite first and second ends in its length direction. The third busbar 46 extends from the container member 31 through the second busbar holder 33, and the first end of the third busbar 46 on the second direction side in the X direction is exposed from the extended end of the second busbar holder 33 on the second direction side in the X direction. The exposed first end of the third busbar 46 is formed as the output terminal 44 of the third busbar 46.

[0062] Similarly, the fourth busbar 47 has opposite first and second ends in its length direction. The fourth busbar 47 extends from the container member 31 through the second busbar holder 33, and the first end of the fourth busbar 47 on the second direction side in the X direction is exposed from the extended end of the second busbar holder 33 on the second direction side in the X direction. The exposed first end of the fourth busbar 47 is formed as the output terminal 44 of the fourth busbar 47.

[0063] refer to Figure 1 , Figure 3 and Figure 6 , each of the busbars 41, 42, 46, 47 is arranged to extend in the coil case 3 toward the first direction side of the Z direction, so that the second end of each of the busbars 41, 42, 46, 47 used as the connection terminal 45 protrudes from the peripheral edge 311a of the top wall 311 of the container member 31 of the coil case 3. In particular, the protruding connection terminal 45 of each of the busbars 41, 42, 46, 47 is arranged to face, i.e. overlap, adjacent to a corresponding one of the coil terminals 22 in the X direction. A prescribed portion of the protruding connection terminal 45 of each of the busbars 41, 42, 46, 47 is welded to a corresponding portion of a corresponding one of the coil terminals 22 in the X direction, and a corresponding portion of each of the coil terminals 22 faces a prescribed portion of the protruding connection terminal 45 of a corresponding one of the coil terminals 22 in the X direction.

[0064] For example, Figure 6 As shown, the protruding connection terminal 45 of each of the busbars 41, 42, 46, 47 has a bent convex portion 452 bent toward the corresponding one of the coil terminals 22 so as to be welded with the corresponding portion of the corresponding one of the coil terminals 22 in the X direction, and the corresponding portion of each coil terminal 22 faces the bent convex portion 452 of the protruding connection terminal 45 of the corresponding one of the coil terminals 22. For example, a portion of the connection terminal 45 exposed from the coil housing 3 is bent so that the bent convex portion 451 is easily formed.

[0065] The bent protrusion 452 has, for example, a semicircular protrusion shape toward the corresponding coil terminal 22 , but may preferably have a desired shape that can be easily and / or reliably connected to the corresponding coil terminal 22 .

[0066] In addition, if Figure 1 , Figure 2 , Figure 8 and Fig.10 As shown, the coil housing 3 includes attachment portions 35, each of which is in a shape that can be firmly attached or mounted to the housing 13 of the power converter 10 described later. The attachment portions 35 are positioned across the container member 31 in the X direction. That is, one of the attachment portions 35 is located on the opposite side of the container member 31 in the X direction from the other of the attachment portions 35. Each attachment portion 35 includes a collar 351 configured to be parallel to the Z direction. For example, insert molding is used to form the collar 351 in each attachment portion 35. The collar 351 of each attachment portion 35 has a hole formed therethrough in the Z direction.

[0067] like Figures 7 to 10 As shown, the coil module 1 is used as a component of the power converter 10. The power converter 10 includes: the coil module 1; a power converter circuit 120 having a switch SW; and a circuit board 12 to which the coil module 1 is connected and on which the power converter circuit 120 is mounted. The coil module 1 is electrically connected to the circuit board 12 via the third bus bar 46 and the fourth bus bar 47.

[0068] In particular, refer to Figure 7 Coil module 1 is connected between circuit board 12 and DC power source BAT having positive and negative electrodes via wiring members 14, 15P, 15N. Wiring members 14, 15P, 15N include positive input wiring member 15P, negative input wiring member 15N and external connection wiring member 14.

[0069] Specifically, input terminal 43 of first bus bar 41 of coil module 1 is connected to the positive electrode of DC power supply BAT via positive input wiring member 15P, and input terminal 44 of second bus bar 42 of coil module 1 is connected to the negative electrode of DC power supply BAT via negative input wiring member 15N.

[0070] The power converter 10 further includes a filter capacitor 15C connected between the input wiring members 15P and 15N in parallel with the DC power supply BAT. The filter capacitor 15C and the coil device 2 of the coil module 1 serve as a filter circuit for reducing noise included in the input DC power supplied from the DC power supply BAT.

[0071] The power converter circuit 120 includes a controller CO, and the controller CO is configured to perform an on / off operation of each switch SW, thereby converting the input DC power supplied from the DC power supply BAT into output power. For example, the controller CO can perform an on / off operation of each switch SW of the power converter 10, so that the power converter 10 functions as a DC-DC power converter that converts an input voltage of the input DC power into an output voltage of the output DC power, and the output voltage is different from the input voltage.

[0072] As another example, the controller CO performs an on / off operation of each switch SW, thereby converting input DC power into alternating current (AC) power.

[0073] As external connection wiring member 14, a busbar-shaped connection wiring member or a linear-shaped wiring member can be used.

[0074] The coil device 2 is arranged so as not to cover the circuit board 12 in the normal direction of the main surface of the circuit board 12 (see, for example, Figure 8 In particular, the coil module 1 according to the first embodiment is arranged so as not to cover the circuit board 12 when viewed in the normal direction corresponding to the Z direction (for example, see Figure 8 ). The coil module 1 may be arranged such that a portion of the coil module 1 , such as a portion of the coil housing 3 , covers the circuit board 12 in the Y direction.

[0075] In addition, for example, Fig. 9 As shown, the coil device 2 is arranged to face the circuit board 12 in the Y direction so that when viewed from the X direction, a virtual line extending from the circuit board 12 in the Y direction passes through the coil device 2. In other words, when viewed from the X direction, the coil device 2 is positioned across the virtual line extending from the circuit board 12 in the Y direction.

[0076] like Figures 8 to 10As shown, the power converter 10 includes a converter housing 13 having a rectangular parallelepiped hollow cavity defined therein. The power converter 10 also includes a coil module 1 and a circuit board 12 mounted in the converter housing 13 .

[0077] As described above, the coil case 3 includes the attachment portion 35 , and the coil module 1 is fixed to the converter case 13 by, for example, the bolts 132 passing through the attachment portion 35 .

[0078] For example, the converter housing 13 has a bottom wall 13a in the Z direction, and an annular boss 131 is provided on the bottom wall 13a to protrude from the bottom wall 13a toward the first direction side in the Z direction, wherein each boss 131 has an axial female thread portion therein. The arrangement of the annular boss 131 is consistent with the arrangement of the collar 351 of the attachment portion 35. That is, the attachment portions 35 of the coil module 1 are respectively mounted on the annular boss 131, and the collar 351 is aligned with the female thread portion of the corresponding annular boss 131, and the bolt 132 can be threadedly assembled in the female thread portion of the corresponding annular boss 131 via the collar 351, so that the coil module 1 is fastened to the inverter housing 13.

[0079] The circuit board 12 is also fastened to the converter case 13 by, for example, bolts, whose illustration is omitted. Note that the normal direction of the main surface of the circuit board 12 is the same as the normal direction of the opening wall 311 of the container member 31, that is, the Z direction.

[0080] Next, how the coil module 1 works is described below, and benefits obtained by the configuration and operation of the coil module 1 are also described.

[0081] The coil module 1 according to the first embodiment includes: a coil device 2; a coil case 3 configured to accommodate the coil device 2; and bus bars 4 fixed to the coil case 3. Coil terminals 22 extending from the coil device 2 are electrically connected to corresponding bus bars 4.

[0082] This configuration of the coil module 1 enables the coil device 2 to be electrically connected to the circuit board 12 via at least one bus bar 4. Therefore, this allows the coil device 2 to have a higher degree of flexibility in arrangement. That is, this configuration of the coil module 1 increases the degree of flexibility in arrangement of the coil device 2 in the power converter 10.

[0083] The coil component 21 includes an embedded portion that is embedded in the potting member 5 and an exposed portion 213 that is exposed from the potting member 5. In other words, at least a portion of the coil component 21 is arranged to be exposed from the potting member 5. This results in a reduction in the number of adjacent winding portions in the coil component 21 between which a portion of the potting member 5 is interposed, so that the generation of a capacitance component between adjacent winding portions in the coil component 21 can be prevented.

[0084] If the entire coil assembly 21 is embedded in the potting member 5, the capacitance value of the capacitance component generated between adjacent winding portions in the coil assembly 21 will become higher, which may deteriorate the high-frequency removal capability of the coil device 2. From this point of view, the coil assembly 21 including the exposed portion 213 exposed from the potting member 5 leads to an improvement in the filtering performance of the coil device 2, making it possible to easily reduce the size of the coil device 2.

[0085] The exposed portion 213 of the coil component 21 has a predetermined length in the normal direction of the top surface 51 of the holding member 5 parallel to the Z direction, and the length of the exposed portion 213 is set to be equal to or greater than half of the length of the coil component 21 in the normal direction, that is, the Z direction. In other words, the length of the exposed portion 213 is set to be greater than or equal to 0.5 times the length of the coil component 21 in the normal direction, that is, the Z direction.

[0086] That is, Figure 4 As shown, the length d1 of the exposed portion 213 of the coil component 21 in the Z direction and the length d2 of the embedded portion of the coil component 21 in the Z direction have a relationship of d1≥d2. This results in the size of the exposed portion 231 of the coil component 21 becoming larger, so that the coil device 2 can have higher filtering performance.

[0087] The coil device 2 is arranged so as not to cover the circuit board 12 in the Z direction, which corresponds to the normal direction of the main surface of the circuit board 12 (see FIG. Figure 8 This arrangement eliminates the need to ensure a large space in the normal direction of the main surface of the circuit board 12, that is, in the thickness direction of the circuit board 12, so that when a large-sized coil device is installed in the coil module 1, the size of the power converter 10 in the thickness direction of the circuit board 12 can be maintained as small as possible.

[0088] In addition, the coil case 3 includes an attachment portion 35. This enables the coil module 1 to be fastened to the converter case 13 through the attachment portion 35. This results in a reduction in vibration of at least the coil module 1.

[0089] As described above, the first embodiment provides a coil module 1 having a higher degree of arrangement flexibility of the coil device 2 , and also provides a power converter 10 including the coil module 1 .

[0090] Second embodiment

[0091] The following references Figure 11 to Figure 12 The second embodiment of the present disclosure will be described. The configuration and function of the coil module 1A according to the second embodiment differ from the configuration and function of the coil module 1 according to the first embodiment mainly in the following points. Therefore, the following mainly describes the different points.

[0092] like Fig.11 As shown, the protruding connection terminal 45 of each of the busbars 41, 42, 46, and 47 exposed from the coil housing 3 has a stress relief portion 451, and the stress relief portion 451 is positioned, for example, adjacent to the bent convex portion 452. The stress relief portion 451 is configured to be bent toward the second direction side of the X direction, which is opposite to the protruding direction of the bent convex portion 452, that is, the first direction side of the X direction. For example, a portion of the connection terminal 45 exposed from the coil housing 3 is bent so that the stress relief portion 451 is easily formed.

[0093] The stress relieving portion 451 is positioned lower than the connection portion between the connection terminal 45 and the corresponding coil terminal 22 in the Z direction. That is, the stress relieving portion 451 is located between the connection portion between the connection terminal 45 and the corresponding coil terminal 22 and the fixing portion between the connection terminal 45 and the coil case 3.

[0094] The stress relieving portion 451 of the connection terminal 45 functions to absorb both the thickness stress applied to the connection terminal 45 in the thickness direction of the connection terminal 45 and the Z-direction stress applied to the connection terminal 45 in the Z-direction. For example, the stress relieving portion 451 of the connection terminal 45 functions to absorb:

[0095] (1) welding-related stress applied to the connection terminals 45 when the connection terminals 45 are welded to the corresponding coil terminals 22;

[0096] (2) vibration stress applied to the connection terminal 45 due to vibration of the coil module 1 under the use conditions of the coil module 1;

[0097] (3) Thermal stress applied to the connection terminal 45 due to vibration of the coil module 1 under the use conditions of the coil module 1 .

[0098] This therefore allows the stresses applied to the connection terminals 45 to be relaxed.

[0099] In addition, the coil module 1A of the second embodiment achieves the same benefits as those achieved by the coil module 1 .

[0100] Modification of the Second Embodiment

[0101] A coil module 1B according to a modification of the second embodiment is described below. Similar or equivalent parts to which the same reference numerals are assigned are omitted or simplified between this modification and the second embodiment to avoid redundant description.

[0102] refer to Fig.12The coil module 1B is configured such that no potting member is filled in the coil case 3. Vibration of the coil module 1B causes stress generated by the vibration to be likely to be applied to the connection portion between each connection terminal 45 and the corresponding coil terminal 22.

[0103] From this point of view, as in the second embodiment, the protruding connection terminal 45 of each of the bus bars 41, 42, 46, 47 exposed from the coil case 3 of the coil module 1B according to this modification has a stress relieving portion 451 positioned, for example, adjacent to the bent convex portion 452. Therefore, the stress relieving portion 451 of each connection terminal 45 functions to absorb stress generated by vibration of the coil module 1B applied to the connection portion between the corresponding connection terminal 45 and the corresponding coil terminal 22.

[0104] That is, although the coil module 1B may have difficulty in reducing the relative displacement between the coil case 3 and the coil device 2 , the coil module 1B makes it possible to relax the stress applied to the connection between the corresponding connection terminal 45 and the corresponding coil terminal 22 when such relative displacement occurs.

[0105] Third embodiment

[0106] The following references Figure 13 to Figure 14 The third embodiment of the present disclosure will be described. The configuration and function of the power converter 100 according to the third embodiment differ from the configuration and function of the power converter 10 according to the first embodiment mainly in the following points. Therefore, the following mainly describes the differences.

[0107] refer to Fig.13 and Fig.14 , the power converter 100 is configured such that the electric components 125 , 130 , 140 are installed in the converter case 13 in addition to the coil module 1 .

[0108] For example, the power converter 100 according to the third embodiment includes: a DC-DC converter as the electric component 125 ; a charger as the electric component 130 ; and a relay as the electric component 140 .

[0109] The DC-DC converter 125 includes, for example, a circuit board 125a on which a transformer and a switch are mounted. The charger 130 includes, for example, a circuit board 130a on which a DC power source is mounted.

[0110] The coil module 1 is connected to at least one of the circuit board 125 a of the DC-DC converter 125 and the circuit board 130 a of the charger 130 via the output terminal 44 of the third bus bar 46 and the fourth bus bar 47 .

[0111] The DC-DC converter 125 is configured to step up or step down the voltage of the DC power input from the coil module 1 to the DC-DC converter 125 when the coil module 1 is connected to the DC-DC converter 125. The stepped-down DC power may be supplied to the power converter circuit 125 of the circuit module 12.

[0112] The charger 130 is configured to rectify the AC power input to the charger 130 into DC power and store the converted DC power in the DC power supply, thereby charging the DC power supply. The charger 130 is also configured to store the DC power input from the coil module 1, thereby charging the DC power supply when the coil module 1 is connected to the charger 130.

[0113] exist Fig.13 and Fig.14 In each of the embodiments, the connection line between the coil module 1 and each of the electric components 125 , 130 , 140 is omitted.

[0114] The coil device 2 of the coil module 1 is arranged such that the coil device 2 does not cover the circuit board 130 a of the charger 130 in the Z direction.

[0115] The coil module 1 according to the third embodiment includes: a coil device 2; a coil housing 3, the coil housing 3 having the coil device 2 mounted thereon; and a bus bar 4, the bus bar 4 being fixed to the coil housing 3. This configuration of the coil module 1 enables the coil device 2 to be electrically connected to at least one of the electrical components 125, 130 via at least one bus bar 4. Therefore, this enables the coil device 2 to have a higher degree of arrangement flexibility in the arrangement in the converter housing 13 of the power converter 100. That is, this configuration of the coil module 1 increases the degree of arrangement flexibility of the coil device 2 in the power converter 100 having the electrical components 125, 130, 140 mounted thereon.

[0116] In addition, the coil module 1 of the third embodiment achieves the same benefits as those achieved by the coil module 1 .

[0117] Although illustrative embodiments of the present disclosure have been described herein, those skilled in the art will appreciate based on the present disclosure that the present disclosure is not limited to the embodiments described herein, but includes any and all embodiments with variations, omissions, combinations (e.g., across aspects of different embodiments), additions, and / or substitutions. The limitations in the claims are to be interpreted broadly based on the language employed in the claims, and are not limited to the examples described in this specification or during the examination of this application, which are understood to be non-exclusive.

Claims

1. A coil module, comprising: a coil device having a coil unit and at least one terminal extending from the coil unit; a housing configured to accommodate the coil arrangement; at least one bus bar, at least one of the bus bars being fixed to the housing, at least one of the terminals being electrically connected to the at least one bus bar; as well as a potting member filled in the housing to firmly hold the coil device in the housing, at least one of the terminals extends from the coil unit in a reference direction to be exposed from the housing through an opening of the second wall of the housing; at least one of the bus bars is embedded in the housing, and at least one prescribed portion of at least one of the bus bars is exposed from the housing to extend along the reference direction to adjacently face at least one of the terminals; at least one of the prescribed portions of at least one of the bus bars is joined to at least one of the terminals, at least one of the prescribed portions of at least one of the busbars has a protrusion toward at least one of the terminals, The protrusion of at least one prescribed portion of at least one of the bus bars is engaged to at least one of the terminals.

2. The coil module according to claim 1, characterized in that: The coil device comprises: an embedding portion, the embedding portion being embedded in the potting member; and An exposed portion is exposed from the potting member.

3. The coil module according to claim 2, characterized in that: The housing comprises: First wall; a second wall, the second wall being opposite to the first wall and having an opening; and a reference axis defined between the first wall and the second wall; The potting member filled in the housing has a surface on the reference axis; The coil unit has a first length in a normal direction of the surface of the potting member; The exposed portion of the coil device has a second length in a normal direction of the surface of the potting member, the second length being equal to or greater than half of the first length of the coil unit.

4. The coil module according to any one of claims 1 to 3, characterized in that: The coil unit comprises: Iron core; and at least one winding, at least one of the windings being wound around the core; At least one of the terminals comprises: a first terminal and a second terminal extending from at least one of the windings along the reference direction through the opening of the second wall of the housing; at least one of the busbars includes at least a first busbar and a second busbar embedded in the housing, and at least one prescribed portion of each of the first busbar and the second busbar is exposed from the housing; at least one of the prescribed portions of each of the first bus bar and the second bus bar is exposed from the housing to extend in the reference direction to adjacently face a corresponding one of the first terminal and the second terminal extending from at least one of the windings; At least one of the prescribed portions of each of the first bus bar and the second bus bar is joined to a corresponding one of the first terminal and the second terminal extending from at least one of the windings.

5. The coil module according to any one of claims 1 to 3, characterized in that: The coil unit comprises: Iron core; a first winding wound around a first half of the core; and a second winding, the second winding being wound around a second half of the core, At least one of the terminals comprises: a first pair of terminals extending from the first winding along the reference direction through the opening of the second wall of the housing; and a second pair of terminals extending from the second winding along the reference direction through the opening of the second wall of the housing, at least one of the busbars includes first to fourth busbars embedded in the housing, and at least one prescribed portion of each of the first to fourth busbars is exposed from the housing, at least one of the prescribed portions of each of the first to fourth bus bars is exposed from the housing to extend in the reference direction to adjacently face a corresponding one of the terminals extending from the first winding and the second winding, At least one of the prescribed portions of each of the first to fourth bus bars is joined to a corresponding one of the terminals extending from the first winding and the second winding.

6. The coil module according to claim 1, characterized in that: At least one of the prescribed portions of at least one of the bus bars has a stress relief portion that protrudes convexly away from at least one of the terminals for absorbing stress when stress is applied to the at least one of the prescribed portions of at least one of the bus bars.

7. A power converter comprising: The coil module according to any one of claims 1 to 6; as well as A circuit board is provided with at least one switch for power conversion, and the coil module is electrically connected to the circuit board via at least one of the bus bars.

8. The power converter according to claim 7, wherein: The coil device of the coil module is arranged so as not to cover the circuit board in a normal direction of a main surface of the circuit board.

9. The power converter according to claim 7 or 8, characterized in that: The power converter comprises a converter housing, in which the coil module and the circuit board are installed. The case of the coil module includes an attachment portion fixed to the converter case of the power converter.

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