Power converter and method of manufacturing the same

Abstract

The invention relates to a power converter and a method of manufacturing the same. The power converter comprises a power module for converting power, a capacitor, a busbar (1) for connecting the power module with the capacitor, and a housing (2) for accommodating the capacitor. The housing (2) has a cavity portion (4), at least a part of the busbar (1) is arranged in the cavity portion (4), and the cavity portion (4) comprises a thermally conductive material (3).

Description

Technical Field

[0001] This invention relates to a power converter and a method for manufacturing the same. Background Technology

[0002] Traditional power converters feature cooled busbars designed to carry high currents, preventing the melting of the plastic molding material covering the busbars. Specifically, power converters typically include power modules for power conversion and electronic components, such as connected capacitors. High temperatures arise during the operation of the power modules, affecting the busbars and other electronic components, including the connected capacitors. Therefore, temperature management may be necessary. For example, cooling the capacitors and / or the busbars may be required. Traditional busbars are arranged on thermally conductive flexible plates, utilizing a large usable area / mounting surface of the housing. The high flexibility of these thin plates necessitates manual assembly, which is both time-consuming and difficult.

[0003] Patent document 1 (JP2018-166400A) discloses a power conversion device having a switching device for converting input power. The power conversion device also includes a capacitor for smoothing the input power and a cooler for cooling the switching device and the capacitor.

[0004] Patent document citation list

[0005] Patent Document 1: JP2018-166400A Summary of the Invention

[0006] Technical issues

[0007] Therefore, the object of the present invention is to provide a power converter that overcomes the shortcomings of conventional power converters. For example, the object is to provide a power converter with improved cooling efficiency that can be manufactured in a more efficient and preferably automated manner. Furthermore, the object is to provide an optimized manufacturing method for the power converter.

[0008] Solution to the problem

[0009] To address this issue, the features of the independent claims are described. Preferred improvements are described in the dependent claims.

[0010] According to one aspect, the power converter may include: a power module for converting power; a capacitor; a busbar for connecting the power module to the capacitor; and a housing for accommodating the capacitor. The housing may have a cavity, and at least a portion of the busbar may be disposed within or inserted into the cavity, wherein the cavity may include a thermally conductive material placed within it. When the material is placed within the cavity, it is most preferably a viscous liquid, which may, for example, be poured into the cavity. By providing a thermally conductive material for mounting the busbar onto the housing, heat exchange between the busbar and the housing can be improved, allowing the housing to cool the busbar during use. After the busbar is mounted in the cavity, the material is preferably hardened and / or dried, and may exhibit a consistency that can be described as rubbery or the like. The dried and / or hardened thermally conductive material preferably holds the busbar in place and allows heat transfer between the housing and the busbar. In a preferred embodiment, the elastic consistency of the material in its hardened state after assembly allows it to withstand vibrations and thermal expansion that occur during use of the power converter, for example, in a vehicle (such as an automobile).

[0011] Thermally conductive materials may include (thermally conductive) resins, silicone, thermally conductive elastomers, and / or gels or thixotropic materials. Thermally conductive resins may be liquid resins. Alternatively, thermal grease may be used as a thermally conductive material. Since thermal grease may not necessarily harden to reliably secure the busbar, in this alternative, additional securing components, such as screws, may preferably be used to secure the busbar assembly to the housing.

[0012] Furthermore, the above arrangement enables convenient automation in the generation of the power converter. This arrangement also allows, for example, the replacement of conventional hot plates used for cooling the busbars. Preferably, the cavity extends vertically to increase the mounting space of the housing and improve its cooling performance. Thus, the vertical portion of the busbar is inserted into the cavity, which may have at least four sides and a bottom surface. This increased area of ​​heat transfer surface (compared to conventional hot plates) allows for improved thermal conductivity cooling, and the busbar can be inserted in a highly automated manner by machine.

[0013] Preferably, one end of the busbar is inserted into the cavity portion, and the busbar is connected to the housing via a thermally conductive material within the cavity portion. Therefore, a thermally conductive material is used as a filler material in the gap between the insertion portion of the busbar and the inner surface of the cavity portion to connect the busbar to the housing. Thus, the thermally conductive material allows the busbar or busbar assembly to be secured to the housing and improves heat transfer between the busbar and the housing. To further increase the connection area between the busbar or busbar assembly and the housing, the cavity portion extends in the vertical direction of the housing when the horizontal direction is the mounting direction of the electronic components of the housing. Since the busbar can be easily and safely positioned in the cavity portion on the housing, this arrangement improves heat transfer and facilitates the production of the power converter. Therefore, heat can be removed from the busbar, while simultaneously automating production. Preferably, the thermally conductive material is elastic. More preferably, the thermally conductive material can be electrically insulating.

[0014] Preferably, the housing has a horizontal mounting surface for mounting components such as electronic components, and one end or tip of the busbar is inserted into the cavity at an angle greater than 0° to the plane of the mounting surface. More preferably, the angle is 90°, and most preferably, the mounting surface is arranged in a horizontal direction, while the busbar (partially) arranged within the cavity extends in a vertical direction. As described above, this preferred arrangement of the cavity / busbar reduces the mounting space required for the busbar. Cooling can be enhanced, while the area occupied by the insulation / cooling unit can be reduced.

[0015] According to a preferred aspect, the busbar is inserted into the cavity portion along its length. In one or more embodiments, the cavity portion may be a bottom hole or a cavity. Preferably, the inner wall surface of the cavity portion may be tapered. More preferably, the cavity portion may be a slot for improving the fixation of the busbar. Preferably, the cavity portion may be manufactured in a casting process, or it may be a milled groove.

[0016] Preferably, the end of the busbar is a plate-shaped projection or portion extending along the projection direction, and the end is inserted into the cavity portion along the projection direction. Furthermore, the projection direction is the length direction of the end.

[0017] The cavity portion can be disposed on the bottom surface of the housing, which extends in the direction of the bottom wall thickness of the housing. Preferably, the depth of the cavity portion is greater than the wall thickness of the housing. The cavity portion can have a bottomed cup shape to reduce the area occupied by this portion in the housing.

[0018] Preferably, the busbar can be at least partially surrounded by a plastic mold to form a busbar assembly, and at least a portion of the busbar assembly can be inserted into the cavity to mount the busbar onto the housing. Most preferably, after the thermally conductive material is completely dry, the portion of the busbar mounted in the cavity is completely surrounded by the thermally conductive material. This achieves optimal conductive cooling and reliably holds the busbar within the cavity. The mounting process may involve placing a liquid (high)viscosity thermally conductive material in the cavity, subsequently inserting the end of the busbar into the cavity, and capillary forces drawing the liquid to the edge of the cavity opening. As a result, the thermally conductive material surrounds the inserted busbar portion and subsequently hardens. Heat treatment can activate / enhance / initiate the hardening process.

[0019] The insertion cavity portion of the busbar assembly is preferably surrounded by a thermally conductive material. More preferably, the thermally conductive material is disposed on at least two opposite sides of the busbar assembly and / or the busbar. Preferably, the thermally conductive material can be disposed on at least two adjacent sides of the busbar assembly and / or the busbar. Therefore, heat can be removed from at least both sides of the busbar or busbar assembly.

[0020] Preferably, the connecting portion of the busbar assembly is inserted into the cavity portion so that the connecting portion does not directly contact the housing. Therefore, thermally conductive material is continuously disposed on the circumference of the connecting portion. In other words, the gap between the connecting portion and the cavity portion is filled with thermally conductive material. More preferably, the gap between the connecting portion and the cavity portion is a constant gap with a constant width, preferably greater than 0.5 mm and less than 2 mm.

[0021] In another preferred embodiment, the busbar is specifically secured to the housing by being mounted in at least one cavity. More preferably, the busbar assembly is connected to the housing solely by a thermally conductive material. In this case, the thermally conductive material is preferably a material that has been hardened over a period of time or after heat treatment, so that the busbar is held in place by the hardened material.

[0022] Preferably, in this case, the thermally conductive material may include resin, silicon, etc.

[0023] Preferably, the busbar assembly has a connecting portion that inserts into the cavity, and the connecting portion is the free end of the busbar assembly. The connecting portion may have a circumferential connecting area for contacting thermally conductive material when mounted in the housing, and the connecting area is designed so that the temperature of the capacitor can be cooled to below 100°C when the power module is operating. Therefore, the extent of the connecting area is designed to allow sufficient heat transfer between the busbar assembly and the housing (or cooler) so that the temperature of the capacitor connected to the busbar can be maintained below 100°C when the power converter is operating (preferably under the maximum load of the power converter).

[0024] Preferably, the housing has a mounting orientation along which electronic components are mounted. The busbar can be inserted into the cavity in a direction different from the mounting orientation to further improve the thermal connection area while ensuring sufficient mounting space for more components to be mounted on the housing.

[0025] Preferably, the housing has a first cavity and a second cavity, and the busbar has a first end and a second end. To mount the busbar onto the housing, the first end is inserted into the first cavity, and the second end is inserted into the second cavity, more preferably, the first cavity and the second cavity are separate. This arrangement ensures stable arrangement of the busbar and improves heat transfer. Furthermore, it allows for more efficient use of installation space.

[0026] Preferably, the insertion cavity portion of the busbar assembly is continuously surrounded by a thermally conductive material to further improve heat transfer.

[0027] Preferably, the depth of the cavity is greater than the wall thickness of the housing to further improve installation space and heat transfer. In one embodiment, the depth of the cavity is greater than the maximum wall thickness of the housing. The depth of the cavity may also be greater than the wall thickness of the bottom of the housing and / or greater than the minimum wall thickness of the housing. The depth of the cavity is greater than the wall thickness of the mounting surface of the housing. The wall thickness of the housing can be the thickness between the outer and inner wall surfaces of the housing, measured perpendicular to the length direction of the wall extension or the main axis or arm.

[0028] Preferably, a thermally conductive material is disposed on at least two different sides of the busbar assembly. Therefore, heat can be removed from the busbar from at least two different sides of the busbar assembly. The sides may extend in the vertical direction (insertion direction), and the bottom surface of the housing may extend in the horizontal direction.

[0029] In one or more embodiments, the cavity portion may be formed on the side of the housing. The housing may be cup-shaped and may have sides and a bottom surface.

[0030] Preferably, the busbar assembly is formed of at least two busbars parallel to each other, each busbar being at least partially surrounded by a plastic mold. In the connecting portion, it is preferable to provide each of the at least two busbars. The busbar assembly may include at least two busbars arranged separately from each other.

[0031] Preferably, the cavity portion has at least two sides and a bottom surface, and the area of ​​the bottom surface is smaller than the area of ​​the sides. The cavity portion may have at least four sides, and the total area of ​​the sides may be larger than the area of ​​the bottom surface.

[0032] Preferably, the cavity portion is partially filled with a heat-conducting material. More preferably, the space between the mounting portion and the inner wall surface of the cavity portion is completely filled with a heat-conducting material.

[0033] A method for manufacturing a power converter may include the steps of dispensing thermally conductive material into a cavity portion, preferably automatically or by machine, and inserting a busbar into a housing by accommodating at least one end of the busbar in the cavity portion.

[0034] The end of the manifold can be pressed into the cavity to allow the thermally conductive material to expand in the gap between the cavity and the portion of the manifold disposed within the cavity. Preferably, the thermally conductive material expands to completely fill the gap, leaving no voids. Alternatively, the manifold is not pressed into the cavity, and the material fills the gap between the housing and the portion of the manifold within the cavity solely through capillary force.

[0035] Beneficial effects of the invention

[0036] In summary, a solution is provided that allows for an improved power converter and a method for manufacturing the power converter. The technical advantage lies in the elimination of conventional partitions and heat-conducting plates, which are difficult to handle during assembly and require manual assembly. Instead, the busbar is at least partially inserted into the cavity surrounding the busbar. A thermally conductive material is arranged in the gap between the housing and the busbar in the cavity, enhancing heat conduction from the busbar to the housing. The area occupied by the busbar and heat conduction unit within the housing is also reduced.

[0037] The subject matter will now be further explained with reference to the accompanying exemplary drawings, based on at least one preferred example, wherein: Attached Figure Description

[0038] Figure 1 An exemplary power converter is described.

[0039] Figure 2 An exemplary installation process for a power converter is described.

[0040] Figure 3 An example of a manifold assembly inserted into a cavity is depicted.

[0041] Figure 4 A sectional view along AA is depicted.

[0042] Figure 5 An assembled power converter according to a preferred example is described.

[0043] Figure 6 An exploded view of the power converter is shown.

[0044] Figure 7 A cross-sectional view of the assembled power converter is depicted.

[0045] Figure 8 The manifold of the cavity inserted into the housing is depicted. Detailed Implementation

[0046] Embodiments and preferred aspects are described in the following sections. However, it should be understood that they are merely examples that may be embodied in various and alternative forms. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to employ the invention in various ways.

[0047] Figure 1 A power converter assembly is shown according to the subject matter for which protection is claimed.

[0048] Busbar 1 is encapsulated in (plastic) mold 5 to form a busbar assembly (in this application, the busbar assembly may be simply referred to as "busbar"). Busbar 1 is provided to carry high current for the power converter assembly and specifically for connecting the power module of the power converter to a capacitor, preferably a smooth capacitor. In order to mount the busbar assembly into the housing 2 of the power converter, at least one cavity 4 is provided in the housing 2.

[0049] To improve cooling efficiency and facilitate the installation of the busbar assembly, a vertically extending cavity 4 for mounting the busbar assembly is used, increasing the limited space available for mounting the busbar assembly at the housing 2. Specifically, the mounting surface MS of the housing 2 is a surface that extends substantially in the horizontal direction. Figure 1 As shown, the horizontal direction is orthogonal to the insertion direction of the busbar 1. Therefore, the cavity portion 4 extends vertically to the horizontal mounting surface MS in the depth or thickness direction of the housing 2. In some embodiments, the mounting surface MS may be the bottom surface of the cup-shaped housing.

[0050] Figure 1 The diagram shows two separate cavity portions 4. To mount the busbar assembly onto the housing 2, the busbar assembly includes a connecting portion AS. The connecting portion AS of the busbar assembly can be inserted into the cavity portion 4 of the housing to mount the busbar assembly to the housing 4. The connecting portion AS is the end of the busbar assembly and has a plate shape extending along a projection direction that is the length direction of the busbar assembly or busbar. To improve heat transfer and facilitate the installation process, the busbar assembly is inserted into the cavity portion along said projection direction. The projection direction is in... Figure 1 It is represented by an arrow with the number "1". Figure 1 The busbar assembly has two separate connecting parts AS, namely a first end 5A and a second end 5B for insertion into the corresponding first and second cavity parts 4A and 4B.

[0051] Heat is generated during the operation of the power converter / busbar assembly. Therefore, the busbar 1 and the plastic mold 5 may experience temperature rise during power converter operation. To further improve the heat dissipation of the busbar assembly, it is recommended to increase heat transfer between the busbar assembly and the housing 2. Specifically, it is recommended to provide a thermally conductive material 3 in the cavity portion 4 of the housing 2. The busbar assembly, more specifically its connecting portion AS, is inserted into the cavity portion 4 containing the thermally conductive material 3. Therefore, in the installed state, the connecting portion AS of the busbar assembly is embedded with the thermally conductive material, which serves to fix the busbar assembly to the housing 3 and to improve the cooling efficiency of the power converter assembly. Thus, the heat generated during the operation of the busbar assembly can be transferred from the busbar assembly to the housing 2 via the thermally conductive material. The housing can also be used as a heat sink or cooler.

[0052] Figure 1 The busbar assembly shown has a horseshoe or U-shaped cross-section. To connect the busbar assembly to the housing, the open end of the U-shape is inserted into the corresponding cavity. This further improves heat transfer and optimizes installation accuracy, while also facilitating installation. The connecting portion AS of the busbar assembly is inserted along its length into each cavity 4 of the housing 2, preferably maintaining a constant gap G between the busbar assembly and the inner wall of the cavity 4.

[0053] It is known that using materials such as (thermally conductive) resins, silicone, thermally conductive elastomers, and / or gels (thixotropic materials) as thermally conductive materials can achieve particularly improved heat transfer performance while ensuring secure fixation of the busbar assembly. The thermally conductive resin can be a liquid resin. In an alternative arrangement, thermal grease can be used as a thermally conductive material that does not necessarily harden and at least cannot adequately fix the busbar, such that when thermal grease is used as a thermally conductive material, additional fixing components, such as screws, are preferably used to secure the busbar assembly to the housing.

[0054] Figure 2 The diagram illustrates the steps for installing a power converter. Specifically, during the assembly of the power converter, the busbar 1 can be partially inserted into the corresponding cavity 4 to improve heat transfer and optimize the arrangement of the busbar 1. Therefore, during the assembly of the power converter in the first step, thermally conductive material can be filled into the cavity 4. This is in Figure 2 This is illustrated in the diagram as step 1. The thermally conductive material can be, for example, a potting compound.

[0055] In the following steps, such as Figure 2As shown in step 2, the busbar 1, more specifically a molded busbar, such as a busbar assembly, can be inserted into a cavity containing potting material. The busbar assembly is inserted along the length of the connecting portion. Therefore, the busbar assembly can be securely connected to the housing 2. Since the heat of the busbar 1 can be transferred to the housing for cooling, the housing 2 is also referred to as a cooler. Because the provided cavity allows the busbar assembly to be safely and accurately placed onto the housing 2 automatically, the process of connecting the busbar assembly to the housing 2 can also be automated.

[0056] Figure 3 The diagram shows a busbar assembly inserted into the cavity portion 4. A gap G exists between the busbar assembly and the side wall surface of the cavity portion 4. The gap G is filled with a thermally conductive material 3. Preferably, the gap G is completely filled with the thermally conductive material so that there is no void between the busbar assembly and the cavity portion (cavity portion).

[0057] Figure 3 The busbar assembly includes a first busbar 1A and a second busbar 1B, which are embedded together in the plastic mold 5. The plastic mold 5 completely covers the busbars in its connecting portion. Therefore, in a preferred embodiment, the outer surface of the busbar assembly in the connecting portion AS is formed only by the outer surface of the plastic mold 5. The outer surface of the plastic mold 5 is inserted into the cavity portion 4 and contacts the heat-conducting material 3 disposed in the cavity portion 4.

[0058] Figure 4 Show along Figure 3 A cross-sectional view along line AA. The busbar assembly is inserted into the cavity 4 and surrounded by a thermally conductive material 3. Preferably, a constant gap G or a constant groove is formed between the busbar assembly and the inner wall surface of the cavity 4. If the thermally conductive material 3 provides a constant thickness around the connection portion (e.g., the sides and bottom) of the busbar assembly inserted into the cavity 4, improved heat transfer behavior can be achieved and assembly can be facilitated. The constant thickness also... Figure 4 As shown, the thickness is preferably between 0.5 and 2 mm. The thermally conductive material 3 can fill the gap G, as... Figure 4 The gap G is partially or completely filled as shown. The cross-section of the cavity portion 4 (in the horizontal direction) can have a rectangular shape (in the horizontal and / or vertical directions) to provide an improved constant gap around the connection portion. With the arrangement of the present invention, the use of a hot plate can also be avoided, and only thermally conductive material can be used to connect the busbar components.

[0059] Figure 5An embodiment of the power converter according to the present invention is shown. Electronic components are arranged and mounted in a housing 2. Electrical connectors are arranged on the outer surface of the housing 2 to provide electrical connection with the power converter. Capacitors and / or power modules are arranged and mounted to the housing 2. A busbar assembly is provided to provide electrical connection with the components mounted in the housing 2. Figure 5 In the illustrated embodiment, several different busbar assemblies with corresponding connectors C for electrical connection are provided.

[0060] like Figure 5 As shown, the busbar assembly is arranged vertically between adjacent components mounted on housing 2 and parallel to the side surface of housing 2. Therefore, the busbar assembly can be mounted perpendicular to the mounting surface of housing 2, which can be the bottom surface of the housing. Figure 5 It extends horizontally. The busbar and busbar assembly are inserted into the corresponding cavity along the length of the busbar. Figure 5 In the middle, the length direction can be parallel to the side wall surface of the shell 2.

[0061] like Figure 6 As shown, the busbar assembly can be a straight bar, plate, or vertical bar extending along its length (which is also the insertion direction). Therefore, the area occupied by the busbar assembly on the housing surface can be further reduced. Preferably, the vertical busbar can be integrated into the die-cast housing. The busbar assembly can also have an L-shaped cross-section (the shape of the letter "L"). One end of the L-shaped busbar can be inserted into the cavity for mounting the busbar assembly to the housing.

[0062] Figure 6 Each different busbar assembly shown has its own end, which is a connection portion for connecting the respective busbar assembly to housing 2. The end of the busbar assembly is positioned opposite the connector C of the busbar assembly. Figure 6 As shown, the busbar assembly BA1 can have a flat plate shape with a connector C at one end and a connecting portion AS at the opposite end. Figure 6 The second busbar assembly BA2 has a T-shaped cross-section, wherein the connector C is positioned opposite the connecting portion AS. Figure 6 In the figure, each connecting part AS has a corresponding thermally conductive material 3. The thermally conductive material 3 shown can be provided in the cavity of the housing 2 before the connecting part AS is inserted into the cavity part 4.

[0063] Figure 7 The image shows a cross-sectional view of the assembled power converter. The first and second busbars 1A and 1B of the busbar assembly BA1 are inserted into the cavity 4 of the housing 2. The busbar assembly is mounted to the housing 2 solely through a connection via the cavity 4 and the thermally conductive material 3. Figure 7 and Figure 8As shown, the thermally conductive material 3 is configured to surround the entire connection portion AS of the busbar assembly BA1. Figure 7 As shown, a single rectangular cavity portion is preferably provided for fixing a busbar assembly. In another embodiment, the cross-sectional shape of the cavity (in the direction perpendicular to the insertion direction of the busbar connection portion) can be circular or elliptical to further improve installation accuracy. The cavity portion can be a molded cavity or a milled cavity.

[0064] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the language used in this specification is descriptive rather than limiting, and is to be understood that various changes may be made without departing from the scope of protection defined by the claims as interpreted according to the disclosure provided herein. Furthermore, features of various implementation embodiments may be combined to form further embodiments of the invention.

Claims

1. A power converter, comprising: an electric power module for converting electric power; a capacitor; a busbar (1) for connecting the power module with the capacitor; and a housing (2) for accommodating the capacitor, the power converter being characterized in that a cavity portion (4) is provided in the housing (2), wherein at least a portion of the busbar (1) is arranged in the cavity portion (4), and a thermally conductive material (3) is provided in the cavity portion (4), the depth of the cavity portion (4) is greater than the wall thickness of the housing (2).

2. The power converter according to claim 1, characterized in that one end portion of the busbar (1) is arranged in the cavity portion (4), and the busbar (1) is thermally connected to the housing (2) via the thermally conductive material (3).

3. The power converter according to claim 2, characterized in that the end portion of the busbar (1) is a plate-shaped projection extending along a projection direction, and the end portion is inserted into the cavity portion (4) along the projection direction.

4. The power converter according to claim 3, characterized in that the housing (2) has a mounting surface (MS) for mounting electronic components, and when mounted in the cavity portion (4), the plane of the mounting surface (MS) forms an angle with the projection direction of the end portion of the busbar (1) which is greater than 0°.

5. The power converter according to claim 1, characterized in that the busbar (1) is at least partially surrounded by a plastic mold (5) to form a busbar assembly, and at least a portion of the busbar assembly is inserted into the cavity portion (4) to mount the busbar (1) on the housing (2).

6. The power converter according to claim 5, characterized in that the busbar assembly has a connection portion (AS) which is inserted into the cavity portion (4), and the connection portion (AS) is a free end portion of the busbar assembly.

7. The power converter according to claim 6, characterized in that the busbar assembly is inserted into the cavity portion (4) along the length direction of the connection portion (AS).

8. The power converter according to claim 5, characterized in that the portion of the busbar assembly which is inserted into the cavity portion (4) is at least partially surrounded by the thermally conductive material (3) on opposite sides.

9. The power converter according to claim 6 or 7, characterized in that the connection portion (AS) is inserted into the cavity portion (4) such that the connection portion (AS) does not directly contact the housing (2).

10. The power converter according to claim 1, characterized in that the busbar (1) is mounted in the cavity portion (4) via the thermally conductive material (3) so as to be exclusively fixed to the housing (2).

11. The power converter according to claim 1, characterized in that the housing (2) has a mounting direction along which adjacent electronic components are mounted on the housing (2), and the busbar (1) is inserted into the cavity portion (4) in a direction different from the mounting direction. ​ 12. The power converter of claim 1, characterized in that the housing (2) has a first cavity portion (4A) and a second cavity portion (4B), the busbar (1) has a first end portion (5A) and a second end portion (5B), for mounting the busbar (1) to the housing (2) the first end portion (5A) is inserted into the first cavity portion (4A) and the second end portion (5B) is inserted into the second cavity portion (4B), wherein the first cavity portion (4A) is separated from the second cavity portion (4B).

13. The power converter of claim 5, characterized in that the thermally conductive material (3) is arranged on at least two different sides of the busbar assembly and / or busbar (1).

14. The power converter of claim 1, characterized in that the cavity portion (4) is formed in a side of the housing (2).

15. The power converter of claim 5, characterized in that the busbar assembly has a cross section in the shape of a horseshoe or L.

16. The power converter of claim 1, characterized in that a gap (G) is arranged between the cavity portion (4) and the portion of the busbar (1) arranged in the cavity portion (4), wherein the gap (G) has a width greater than 0.5 mm and / or less than 2 mm.

17. The power converter of claim 1, characterized in that the thermally conductive material (3) is a thermally conductive elastomer.

18. A method for manufacturing the power converter of any one of claims 1 to 17, characterized in that, comprising the steps of - dispensing the thermally conductive material (3) into the cavity portion (4); and - molding the busbar (1) on the housing (2) by receiving at least one end portion of the busbar (1) in the cavity portion (4).

19. The method of claim 18, characterized in that the end portion of the busbar (1) is pressed into the cavity portion (4) to cause the thermally conductive material (3) to expand in a gap (G) between the cavity portion (4) and the portion of the busbar (1) arranged in the cavity portion (4).

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