Power conversion device, motor module, and method for manufacturing power conversion device

Abstract

The present invention is provided with: a bus bar extending in a first direction; a sensor that detects a magnetic field generated by a current flowing through the bus bar; a shield core having magnetism and surrounding the bus bar and the sensor from both sides in a second direction orthogonal to the first direction and at least one side in a third direction orthogonal to the first direction and the second direction; a core sealing part that seals at least a portion of the shield core with a resin; and a support portion. The shield core is fixed to the support portion via the core sealing portion.

Description

Technical Field

[0001] The present invention relates to a power conversion device, a motor module, and a method for manufacturing a power conversion device. Background Art

[0002] As a power conversion device for supplying power to a motor, for example, a power conversion device is known as described in Patent Document 1, which includes a bus bar and a sensor (Hall IC) for detecting a current value flowing through the bus bar inside a shielding core that collects a magnetic field generated by a current flowing through the bus bar.

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2010-8050 Summary of the Invention

[0006] Problems to be Solved by the Invention

[0007] When the shielding core is composed of a plurality of magnetic metal plates laminated in the plate thickness direction, the dimensional tolerance of the shielding core tends to increase. Therefore, when the shielding core is fixed to a resin support portion or the like by press-fitting, it is difficult to easily press-fit the shielding core into the support portion or the like due to the dimensional tolerance of the shielding core, and thus the manufacturing man-hours and manufacturing costs of the power conversion device may increase.

[0008] In view of the above circumstances, one of the objects of one aspect of the present invention is to provide a power conversion device and a motor module capable of easily fixing a shielding core to a support portion. Another object of one aspect of the present invention is to provide a method for manufacturing a power conversion device capable of easily fixing a shielding core to a support portion.

[0009] Means for Solving the Problems

[0010] One aspect of the power conversion device of the present invention includes: a bus bar extending in a first direction; a sensor for detecting a magnetic field generated by a current flowing through the bus bar; a shielding core having magnetism and surrounding the bus bar and the sensor from both sides in a second direction orthogonal to the first direction and at least one side in a third direction orthogonal to the first direction and the second direction; a core sealing portion for sealing at least a part of the shielding core with resin; and a support portion. The shielding core is fixed to the support portion via the core sealing portion.

[0011] One aspect of the motor module of the present invention includes: the above-described power conversion device; and a motor driven by the above-described power conversion device.

[0012] One aspect of the manufacturing method of the power conversion device of the present invention is a manufacturing method of a power conversion device including a magnetic shielding core, a resin core sealing portion, and a support portion, and includes: a positioning step of determining the position of the shielding core relative to the support portion in a mold; and a forming step of forming the core sealing portion that seals at least a part of the shielding core with resin and is fixed to the support portion by injection molding with the support portion and the shielding core as insert parts.

[0013] Advantageous Effects of the Invention

[0014] According to one aspect of the present invention, in a power conversion device and a motor module, the shielding core can be easily fixed to the support portion. Further, according to one aspect of the present invention, in the manufacturing method of a power conversion device, the shielding core can be easily fixed to the support portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic view showing a motor module of one embodiment.

[0016] Figure 2 It is a perspective view showing a part of a power conversion device of one embodiment.

[0017] Figure 3A It is a top view showing a part of a power conversion device of one embodiment.

[0018] Figure 3B It is a cross-sectional view showing a power conversion device of one embodiment.

[0019] Figure 4 It is a top view showing a support portion and a shielding core of one embodiment.

[0020] Figure 5A It is a flowchart showing a manufacturing method of a power conversion device of one embodiment.

[0021] Figure 5B It is a first cross-sectional view showing a manufacturing method of a power conversion device of one embodiment.

[0022] Figure 5C It is a second cross-sectional view showing a manufacturing method of a power conversion device of one embodiment.

[0023] Figure 5D It is a third cross-sectional view showing a manufacturing method of a power conversion device of one embodiment.

[0024] Figure 6A It is a top view showing a part of a power conversion device of Modification 1 of one embodiment.

[0025] Figure 6BIt is a cross-sectional view of a power conversion device showing Modification Example 1 of an embodiment.

[0026] Figure 7A It is a top view of a part of a power conversion device showing Modification Example 2 of an embodiment.

[0027] Figure 7B It is a cross-sectional view of a power conversion device showing Modification Example 2 of an embodiment.

[0028] Figure 8A It is a top view of a part of a power conversion device showing Modification Example 3 of an embodiment.

[0029] Figure 8B It is a cross-sectional view of a power conversion device showing Modification Example 3 of an embodiment.

[0030] Figure 9A It is a top view of a part of a power conversion device showing Modification Example 4 of an embodiment.

[0031] Figure 9B It is a cross-sectional view of a power conversion device showing Modification Example 4 of an embodiment. Detailed Embodiment

[0032] Hereinafter, a power conversion device and a motor module according to an embodiment of the present invention will be described with reference to the drawings. In addition, the scope of the present invention is not limited to the following embodiments and can be arbitrarily changed within the scope of the technical idea of the present invention. In the following drawings, in order to facilitate understanding of each structure, the actual structure, scale, quantity, etc. may sometimes be different.

[0033] In the following description, a first direction D1 is appropriately shown in each figure. The first direction D1 is the direction in which the bus bar extends in the embodiment described below. The first direction D1 is the front-rear direction of the power conversion device. In the following description, the side toward which the arrow of the first direction D1 points (+D1 side) is referred to as "one side of the first direction D1" or "rear side". The side opposite to the side toward which the arrow of the first direction D1 points (-D1 side) is referred to as "the other side of the first direction D1" or "front side".

[0034] In the following description, a second direction D2 is appropriately shown in each figure. In the present embodiment, the second direction D2 is the direction in which a plurality of bus bars are arranged and disposed, and is a direction orthogonal to the first direction D1. The second direction D2 is the left-right direction of the power conversion device. In the following description, the side toward which the arrow of the second direction D2 points (+D2 side) is referred to as "one side of the second direction D2" or "left side". The side opposite to the side toward which the arrow of the second direction D2 points (-D2 side) is referred to as "the other side of the second direction D2" or "right side".

[0035] In the following description, the third direction D3 is appropriately indicated in each figure. In the present embodiment, the third direction D3 is a direction orthogonal to the first direction D1 and the second direction D2. The third direction D3 is the vertical direction of the power conversion device. In the following description, the side toward which the arrow of the third direction D3 points (+D3 side) is referred to as "one side of the third direction D3" or "lower side". The side opposite to the side toward which the arrow of the third direction D3 points (-D2 side) is referred to as "the other side of the third direction D3" or "upper side".

[0036] In addition, the upper side, lower side, front side, rear side, left side, and right side are only names used to explain the relative positional relationship of each part, and the actual configuration relationship, etc. may also be a configuration relationship other than the configuration relationship represented by these names.

[0037] <First Embodiment>

[0038] Figure 1 is a schematic diagram showing the motor module 1 of the present embodiment.

[0039] The motor module 1 is a drive device mounted on a vehicle to rotate the vehicle's axle. The vehicle on which the motor module 1 is mounted is a vehicle powered by a motor, such as a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or an electric vehicle (EV). The motor module 1 includes a motor 2 and a power conversion device 10.

[0040] The motor 2 rotates an axle of the vehicle (not shown). In the present embodiment, the motor 2 is a three-phase motor. The three phases are the U phase, the V phase, and the W phase. The motor 2 has a U-phase coil, a V-phase coil, and a W-phase coil (not shown).

[0041] The power conversion device 10 generates a current supplied to the motor 2 and supplies currents to the U-phase coil, the V-phase coil, and the W-phase coil of the motor 2, respectively. The power conversion device 10 is connected to the motor 2, the control unit 3, and the external power source 4.

[0042] The control unit 3 controls the operation of the vehicle. The control unit 3 sends a control signal including the instruction content related to the operation of the motor 2 to the power conversion device 10. The external power source 4 supplies a direct current to the power conversion device 10. In the present embodiment, the external power source 4 is a battery.

[0043] The power conversion device 10 generates a current with a predetermined waveform based on the control signal sent from the control unit 3, according to the DC current supplied by the external power source 4, and supplies the current to the motor 2. More specifically, the power conversion device 10 generates phase currents (U-phase current, V-phase current, and W-phase current) that are respectively supplied to the U-phase coil, V-phase coil, and W-phase coil of the motor 2. In the present embodiment, the power conversion device 10 is an inverter that converts DC current into AC current. The power conversion device 10 and the motor 2 are connected by three connection lines 6. Each connection line 6 is connected to any one of the U-phase coil, V-phase coil, and W-phase coil of the motor 2, and currents are respectively supplied to the U-phase coil, V-phase coil, and W-phase coil via each connection line 6.

[0044] As Figure 2 shown, the power conversion device 10 includes a housing 11, a support portion 12, an IGBT (Insulated Gate Bipolar Transistor) module 16, a circuit board 20, a sensor 25, a bus bar 30, a shielding core 40, and a core sealing portion 50.

[0045] The housing 11 houses the support portion 12, the IGBT module 16, the circuit board 20, the sensor 25, the bus bar 30, the shielding core 40, and the core sealing portion 50 inside. Although not shown in the figure, the housing 11 is a hollow box shape. In the present embodiment, the housing 11 is made of metal. In the present embodiment, the housing 11 is grounded. The housing 11 has a bottom wall portion 11a.

[0046] The bottom wall portion 11a is a plate shape that extends in a direction orthogonal to the third direction D3. The plate surface of the bottom wall portion 11a faces the third direction D3.

[0047] The IGBT module 16 generates phase currents that are respectively supplied to the U-phase coil, V-phase coil, and W-phase coil of the motor 2 according to the DC current supplied by the external power source 4. The IGBT module 16 has a plurality of electronic components (not shown) such as a plurality of insulated gate bipolar transistors (IGBTs). Although not shown in the figure, the IGBT module 16 is connected to Figure 1 the control unit 3 and the external power source 4 as shown. The IGBT module 16 is fixed to the bottom wall portion 11a.

[0048] As Figure 2 shown, the circuit board 20 is a printed mounting board that extends in a direction orthogonal to the third direction D3. When observed in the third direction D3, the circuit board 20 is substantially rectangular. Although not shown in the figure, the circuit board 20 is connected to Figure 1The control unit 3 shown is connected to the external power supply 4. Although not shown in the figure, a plurality of pins of the IGBT module 16 are connected to the circuit board 20. Thus, the circuit board 20 is electrically connected to the IGBT module 16. A plurality of electronic components and the sensor 25 (not shown) are mounted on the circuit board 20. As Figure 2 shown, a hole portion 20b is provided in the circuit board 20. The circuit board 20 has a substrate protruding portion 20d.

[0049] The hole portion 20b is a hole that penetrates the circuit board 20 in the third direction D3. In the present embodiment, ten hole portions 20b are provided. When the screw 90 passes through each hole portion 20b in the third direction D3 and is screwed into a threaded hole (not shown) of the IGBT module 16, the circuit board 20 is fixed to the IGBT module 16.

[0050] The substrate protruding portion 20d is a portion of the circuit board 20 that protrudes forward (-D1 side). When viewed from the third direction D3, the substrate protruding portion 20d has a substantially rectangular shape. In the present embodiment, three substrate protruding portions 20d are provided. Each substrate protruding portion 20d is arranged at intervals from each other in the second direction D2.

[0051] The support portion 12 has a substantially rectangular parallelepiped shape extending in the third direction D3. As Figure 3A shown, when viewed from the third direction D3, the support portion 12 has a substantially rectangular shape with its long side extending in the second direction D2. In the present embodiment, the support portion 12 is made of metal. In the present embodiment, the support portion 12 is fixed to the upward-facing surface of the bottom wall portion 11a by screws or the like (not shown). Thus, the support portion 12 is grounded via the housing 11. Additionally, the support portion 12 may be connected to the bottom wall portion 11a. In this case, the support portion 12 is a part of the housing 11. As Figure 3B shown, a receiving portion 12c is provided in the support portion 12. The support portion 12 has an upper surface 12a, a support surface 12d, and a plurality of positioning portions 13. The upper surface 12a is the outer surface of the support portion 12 that faces upward, i.e., the other side (-D3 side) of the third direction D3.

[0052] The receiving portion 12c is a hole that depresses from the upper surface 12a downward, i.e., the one side (+D3 side) of the third direction D3. As Figure 4 shown, the receiving portion 12c has a substantially rectangular shape with its long side extending in the second direction D2. As Figure 3B shown, the left end (+D2 side) of the receiving portion 12c is located to the left of the leftmost substrate protruding portion 20d. The right end (-D2 side) of the receiving portion 12c is located to the right of the rightmost substrate protruding portion 20d.

[0053] The support surface 12d is the surface on the other side (-D3 side) of the inner side surface of the accommodation portion 12c facing the third direction D3. The support surface 12d is the bottom surface of the accommodation portion 12c.

[0054] The plurality of positioning portions 13 are rectangular parallelepiped-shaped and protrude upward from the support surface 12d. As Figure 4 shown, when viewed from the third direction D3, each positioning portion 13 has a rectangular shape with its long side extending along the first direction D1. In the present embodiment, six positioning portions 13 are provided. The respective positioning portions 13 are arranged at intervals from each other along the second direction D2.

[0055] As Figure 3B shown, the plurality of positioning portions 13 are grouped in pairs of two adjacent ones in the second direction D2, and three groups are arranged in the second direction D2. For each of the two positioning portions 13 in each group on the right side, the surface facing the left side, that is, one side (+D2 side) of the second direction D2, is the positioning surface 13a. Similarly, for each of the two positioning portions 13 in each group on the left side, the surface facing the right side, that is, the other side of the second direction D2, is the positioning surface 13b. The positioning surface 13a and the positioning surface 13b face each other in the second direction D2. In the following description, the positioning surfaces 13a and 13b facing each other in the second direction D2 are referred to as "a pair of positioning surfaces 13a, 13b". In the present embodiment, the support portion 12 has three pairs of positioning surfaces 13a, 13b. As Figure 4 shown, in the first direction D1, a gap is provided between each of the plurality of positioning portions 13 and the inner side surface of the accommodation portion 12c. That is, in the first direction D1, a gap is provided between each of the pair of positioning surfaces 13a, 13b and the inner side surface of the accommodation portion 12c.

[0056] The bus bar 30 is a path through which the current generated in the IGBT module 16 flows. As Figure 2 shown, the bus bar 30 is plate-shaped and extends along the first direction D1. The bus bar 30 is made of metal. A part of the bus bar 30 is disposed on the lower side (+D3 side) of the circuit board 20. Although not shown, one end of the bus bar 30 is fixed to an unillustrated electrode of the IGBT module 16 by an unillustrated screw. Thus, the phase current flows through the bus bar 30. The other end of the bus bar 30 is located on the front side (-D1 side) of the circuit board 20. Although not shown, the other end of the bus bar 30 is electrically connected to the connection wire 6 (refer to Figure 1 ). In the present embodiment, three bus bars 30 are provided. That is, the power conversion device 10 includes a plurality of bus bars 30. Any one of the U-phase current, the V-phase current, and the W-phase current flows through each bus bar 30. As Figure 3BAs shown, each bus bar 30 is arranged and disposed in the second direction D2. When viewed from the third direction D3, each of the substrate protrusions 20d of the circuit board 20 overlaps with each of the bus bars 30.

[0057] The sensor 25 is a magnetic detection sensor that detects a magnetic field generated by a current flowing through the bus bar 30. In the present embodiment, the sensor 25 is a Hall IC. The sensor 25 converts the magnetic field into a voltage and outputs it. The magnitude of the voltage output from the sensor 25 is related to the magnitude of the current flowing through the bus bar 30. Thus, the magnitude of the current flowing through the bus bar 30 can be detected by the sensor 25. As Figure 2 shown, in the present embodiment, three sensors 25 are provided. That is, the power conversion device 10 includes a plurality of sensors 25. Each sensor 25 is respectively mounted on different substrate protrusions 20d. As Figure 3B shown, each sensor 25 is arranged and disposed in the second direction D2. Each sensor 25 is respectively disposed on the upper side (-D3 side) of the bus bar 30. When viewed from the third direction D3, each sensor 25 overlaps with the approximate center of the bus bar 30 in the second direction D2. Each sensor 25 detects the current values of the U-phase current, V-phase current, and W-phase current flowing through each bus bar 30. The output voltage of each sensor 25 is transmitted to an arithmetic element (not shown) mounted on the circuit board 20, etc., and the magnitude of the current generated by the above-mentioned plurality of electronic elements (not shown) is adjusted based on the output voltage of each sensor 25. Thus, the current supplied to the motor 2 can be stabilized at a desired current value, and the operations of the power conversion device 10 and the motor module 1 can be stabilized.

[0058] The shielding core 40 collects the magnetic field generated by the current flowing through the bus bar 30 and shields the magnetic field from the outside. The shielding core 40 has magnetism. The shielding core 40 is composed of a plurality of magnetic metal plates laminated in the plate thickness direction. In the present embodiment, the shielding core 40 is formed by laminating a plurality of magnetic metal plates in the first direction D1. As the material constituting the shielding core 40, a metal material having a high magnetic permeability such as ferrite or permalloy can be used. In the present embodiment, the shielding core 40 has a first wall portion 40a, a second wall portion 40b, and a third wall portion 40c.

[0059] The first wall portion 40a is a plate shape extending in a direction orthogonal to the third direction D3. The plate surface of the first wall portion 40a faces the third direction D3. As Figure 4 shown, when viewed from the third direction D3, the first wall portion 40a is a rectangular shape with its long side extending in the second direction D2. As Figure 3BAs shown, the first wall portion 40a is disposed on the lower side (+D3 side) of the sensor 25 and the bus bar 30. In the present embodiment, the surface of the first wall portion 40a facing the lower side (+D3 side) contacts the support surface 12d. That is, the shielding core 40 contacts the support surface 12d. The first wall portion 40a is disposed between a pair of positioning surfaces 13a and 13b. The second wall portion 40b and the third wall portion 40c are respectively connected to both end portions of the first wall portion 40a in the second direction D2.

[0060] The second wall portion 40b is a plate-like shape protruding upward (-D3 side) from the end portion on the left side (+D2 side) of the first wall portion 40a. The plate surface of the second wall portion 40b faces the second direction D2. The upper end portion of the second wall portion 40b is located above the sensor 25. The second wall portion 40b is disposed between a pair of positioning surfaces 13a and 13b.

[0061] The third wall portion 40c is a plate-like shape protruding upward (-D3 side) from the end portion on the right side (-D2 side) of the first wall portion 40a. The plate surface of the third wall portion 40c faces the second direction D2. The upper end portion of the third wall portion 40c is located above the sensor 25. The third wall portion 40c is disposed between a pair of positioning surfaces 13a and 13b. As described above, the first wall portion 40a and the second wall portion 40b are disposed between a pair of positioning surfaces 13a and 13b. Therefore, the shielding core 40 is disposed between a pair of positioning surfaces 13a and 13b. The second wall portion 40b and the third wall portion 40c sandwich the bus bar 30, the substrate protrusion 20d, and the sensor 25 mounted on the substrate protrusion 20d from both sides in the second direction D2.

[0062] In the present embodiment, three shielding cores 40 are provided. That is, the power conversion device 10 includes a plurality of shielding cores 40. Each shielding core 40 is arranged and disposed in the second direction D2. One sensor 25 and one bus bar 30 are disposed inside one shielding core 40. The plurality of shielding cores 40 surround one sensor 25 and one bus bar 30 from both sides in the second direction D2 (+D2 side and -D2 side) and one side in the third direction D3 (+D3 side). Therefore, according to the present embodiment, the magnetic field generated by the current flowing through one bus bar 30 is collected by the shielding core 40 surrounding the bus bar 30. Therefore, it is possible to suppress the magnetic field generated by the current flowing through one bus bar 30 from passing through the sensor 25 that detects the current value flowing through the other bus bar 30. Therefore, it is possible to improve the accuracy of each sensor 25 in detecting the current value flowing through each bus bar 30, and thus the operation of the power conversion device 10 and the motor module 1 can be stabilized.

[0063] According to this embodiment, the support portion 12 has a support surface 12d facing the upper side, i.e., the other side (-D3 side) of the third direction D3, and the shielding core 40 is in contact with the support surface 12d. Therefore, the position of the shielding core 40 relative to the support portion 12 in the third direction D3 can be determined with high precision. Thus, in the third direction D3, the positions of the respective shielding cores 40 relative to the sensor 25 and the bus bar 30 can be determined with high precision, and thus the accuracy of detecting the current value flowing through each bus bar 30 by each sensor 25 can be improved more appropriately.

[0064] In addition, in this embodiment, as described above, the support portion 12 is grounded via the housing 11. Therefore, in this embodiment, the radiated noise radiated from each bus bar 30 can be appropriately transmitted to the ground wire via each shielding core 40. Thereby, the radiated noise radiated from each shielding core 40 can be suppressed. Therefore, it is possible to suppress the radiated noise from overlapping each sensor 25, and the accuracy of detecting the current value flowing through each bus bar 30 by each sensor 25 can be improved. Therefore, the operations of the power conversion device 10 and the motor module 1 can be stabilized. In addition, it is possible to suppress the radiated noise from overlapping on the circuit board 20 and the IGBT module 16 respectively, so that the operations of the circuit board 20 and the IGBT module 16 can be stabilized respectively.

[0065] Furthermore, in this embodiment, as described above, the surface of the first wall portion 40a of the shielding core 40 facing the lower side (+D3 side) is in contact with the support surface 12d. That is, since the shielding core 40 and the support portion 12 are in surface contact, the contact area between the shielding core 40 and the support portion 12 can be enlarged, and the impedance between the shielding core 40 and the ground wire can be reduced. Therefore, the radiated noise radiated from the bus bar 30 and the radiated noise radiated from the electrical equipment arranged around the power conversion device 10 can be appropriately transmitted to the ground wire via the shielding core 40. Therefore, it is possible to suppress this radiated noise from overlapping each sensor 25, and thus the operations of the power conversion device 10 and the motor module 1 can be stabilized.

[0066] In addition, the shape of the shielding core 40 observed from the first direction D1 is not limited to the shape of this embodiment. For example, it may be other shapes such as a U-shaped protruding downward (+D3 side). In addition, the shielding core 40 may be configured to surround the sensor 25 and the bus bar 30 not only from both sides in the second direction D2 and one side (+D3 side) in the third direction D3 but also from the other side (-D3 side) in the third direction. In this case, the shielding core 40 is, for example, rectangular when observed from the first direction D1.

[0067] As Figure 3A and Figure 3BAs shown, in the present embodiment, the core sealing portion 50 is disposed inside the accommodating portion 12c of the support portion 12. The core sealing portion 50 is made of resin. The core sealing portion 50 seals, with resin, the lower side portion of the shielding core 40. That is, the core sealing portion 50 seals, with resin, at least a part of the shielding core 40. At least a part of the shielding core 40 is buried inside the core sealing portion 50. As Figure 3A shown, the core sealing portion 50 is in contact with the surface facing the first direction D1 and the surface facing the second direction D2 among the inner side surfaces of the accommodating portion 12c, respectively. In addition, as Figure 3B shown, the core sealing portion 50 is in contact with a part of the support surface 12d facing the third direction D3 among the inner side surfaces of the accommodating portion 12c. Thereby, the core sealing portion 50 is fixed to the accommodating portion 12c. Therefore, each shielding core 40 is fixed to the support portion 12 via the core sealing portion 50.

[0068] In addition, in this specification, "sealing" means filling or burying a gap in a blocking manner into an object. Therefore, the term "sealing" is also used in cases where liquids such as moisture are not allowed to pass through.

[0069] The power conversion device 10 and the motor module 1 according to the present embodiment include: a shielding core 40 having magnetism, surrounding the bus bar 30 and the sensor 25 from both sides in the second direction D2 and one side (+D3 side) in the third direction D3; a core sealing portion 50 that seals at least a part of the shielding core 40 with resin; and a support portion 12, and the shielding core 40 is fixed to the support portion 12 via the core sealing portion 50. Here, in a structure different from that of the present embodiment, in a structure in which the shielding core is assembled to a resin support portion or the like by press-fitting or the like, depending on the dimensional tolerance of the shielding core, it may not be possible to assemble the shielding core to the support portion or the like. In this case, it is necessary to discard the shielding core, increasing the manufacturing cost of the power conversion device. However, in the present embodiment, as described above, the shielding core 40 at least a part of which is sealed by the core sealing portion 50 is fixed to the support portion 12 via the core sealing portion 50. Therefore, even a shielding core with a large dimensional tolerance can be easily fixed to the support portion 12. Therefore, it is possible to use a shielding core 40 with a relatively large dimensional tolerance, and thus it is possible to suppress an increase in the manufacturing man-hours and manufacturing cost of the power conversion device 10 and the motor module 1.

[0070] In addition, in a structure in which the above-described shielding core is assembled to a resin support portion or the like by pressing or the like, burrs are likely to be generated in the support portion or the like. Therefore, burrs are likely to be bitten when the shielding core is assembled to the support portion or the like. In this case, it is difficult to assemble the shielding core to the support portion or the like, so the man-hours for this assembly operation increase. However, in the present embodiment, as described above, the shielding core 40 at least partially sealed by the core sealing portion 50 is fixed to the support portion 12 via the core sealing portion 50, so that the shielding core 40 can be easily fixed to the support portion 12. Therefore, it is possible to more appropriately suppress an increase in man-hours for fixing the shielding core 40 to the support portion 12, and it is possible to suppress an increase in man-hours for manufacturing the power conversion device 10 and the motor module 1.

[0071] According to the present embodiment, a receiving portion 12c that is recessed toward the lower side, i.e., one side (+D3 side) in the third direction D3, is provided on the surface of the support portion 12 facing the upper side, i.e., the other side (-D3 side) in the third direction D3, and the core sealing portion 50 is in contact with the inner side surface of the receiving portion 12c. Thereby, the contact area between the core sealing portion 50 and the support portion 12 can be enlarged, so that the core sealing portion 50 can be more firmly fixed to the support portion 12. Thereby, the shielding core 40 can be more firmly fixed to the support portion 12 via the core sealing portion 50, so that the positions of the respective shielding cores 40 relative to the respective sensors 25 and the respective bus bars 30 can be stabilized. Therefore, the accuracy of detecting the current value flowing through each bus bar 30 by each sensor 25 can be more appropriately improved.

[0072] Next, in the present embodiment, a shielding core fixing process Ps for fixing the shielding core 40 to the support portion 12 will be described. The shielding core fixing process Ps is a part of the manufacturing process of the power conversion device 10 and the motor module 1. As Figure 5A shown, the shielding core fixing process Ps includes: a positioning step S1 of determining the position of the shielding core 40 relative to the support portion 12 in the mold 80; and a molding step S2 of molding a core sealing portion 50 that seals at least a part of the shielding core 40 with resin and is fixed to the support portion 12 by injection molding with the support portion 12 and the shielding core 40 as insert parts. In addition, in the present specification, "operators and the like" include operators who perform each operation, assembly devices, and the like. Each operation may be performed only by an operator, only by an assembly device, or by an operator and an assembly device.

[0073] In the positioning step S1, the operator or the like determines the position of the shielding core 40 relative to the support portion 12 in the mold 80. As Figure 5BAs shown, the operator etc. first dispose each shielding core 40 between the pair of positioning surfaces 13a, 13b of the support portion 12. Thereby, the position of each shielding core 40 in the second direction D2 with respect to the support portion 12 is determined. Further, since the surface of the first wall portion 40a of each shielding core 40 facing the lower side (+D3 side) contacts the support surface 12d, the position of each shielding core 40 in the third direction D3 with respect to the support portion 12 is determined.

[0074] Next, the operator etc. mount the mold 80 on the support portion 12. In the present embodiment, the mold 80 is composed of an upper mold 81 and a lower mold 82. The lower mold 82 has a substantially rectangular parallelepiped shape provided with a lower accommodation portion 82a recessed downward (+D3 side) from the surface facing the upper side (-D3 side). The operator etc. insert the lower portion of the support portion 12 into the inside of the lower accommodation portion 82a and mount the lower mold 82 on the support portion 12.

[0075] The upper mold 81 has a substantially rectangular parallelepiped shape provided with a first accommodation portion 81b recessed upward from the surface facing the lower side. The outer edge of the surface of the first accommodation portion 81b facing the lower side contacts the upper surface 12a of the support portion 12 in the third direction D3. Thereby, the position of the upper mold 81 in the third direction D3 with respect to the support portion 12 is determined. The other part of the surface of the first accommodation portion 81b facing the lower side is opposed to the support surface 12d and the plurality of positioning portions 13 with a gap in the third direction D3. The upper mold 81 is provided with an injection port 81a and a plurality of second accommodation portions 81c.

[0076] The injection port 81a is a hole penetrating the upper mold 81 in the third direction D3. The injection port 81a is provided at substantially the center of the upper mold 81 in the second direction D2. The injection port 81a is located above substantially the center of the support portion 12 in the second direction D2. The plurality of second accommodation portions 81c are respectively holes recessed upward (-D3 side) from the surface of the first accommodation portion 81b facing the lower side. In the present embodiment, six second accommodation portions 81c are provided. The plurality of second accommodation portions 81c are provided at intervals along the second direction D2. The operator etc. insert the upper portion of the support portion 12 into the first accommodation portion 81b, insert the upper portions of the second wall portion 40b and the third wall portion 40c of each shielding core 40 into the respective second accommodation portions 81c, and mount the upper mold 81 on the support portion 12. Additionally, although not shown in the figure, the upper mold 81 has six pairs of opposed portions opposed to each other in the first direction D1. One of the second wall portion 40b and the third wall portion 40c of each shielding core 40 is disposed between each pair of opposed portions. Thereby, the position of each shielding core 40 in the first direction D1 with respect to the support portion 12 and the mold 80 is determined, and the positioning step S1 ends.

[0077] In the forming step S2, an operator or the like performs injection molding with the support portion 12 and the shielding core 40 as insert parts to form the core sealing portion 50. As Figure 5C shown, the operator or the like causes the hot-melted molten resin MR to flow into the inside of the mold 80 from the injection port 81a of the upper mold 81. In the present embodiment, the resin is a thermosetting resin of acrylate. The resin may also be other resins such as thermosetting resins of epoxy type or the like. Further, in the present embodiment, the injection pressure for causing the molten resin MR to flow into the mold 80 is a low pressure of about 0.5 to 15.0 MPa. The molten resin MR flowing into the mold 80 flows on both sides in the second direction D2 inside the accommodation portion 12c. When the molten resin MR fills the entire inside of the accommodation portion 12c, the operator or the like stops the injection of the molten resin MR. After that, the operator or the like cures the molten resin MR by heating it to a predetermined temperature using a heater or the like (not shown), and then removes the mold 80 from the support portion 12. Thus, as Figure 5D shown, the core sealing portion 50 is formed to seal at least a part of each of the shielding cores 40 with the resin. Further, since the outer side surface of the core sealing portion 50 contacts the inner side surface of the accommodation portion 12c, the core sealing portion 50 is fixed to the support portion 12.

[0078] According to the manufacturing method of the power conversion device of the present embodiment, there are provided: a positioning step S1 of determining the position of the shielding core 40 relative to the support portion 12 in the mold 80; and a forming step S2 of forming the core sealing portion 50 that seals at least a part of the shielding core 40 with the resin and is fixed to the support portion 12 by injection molding with the support portion 12 and the shielding core 40 as insert parts. Therefore, the shielding core 40 can be fixed to the support portion 12 via the core sealing portion 50. In a structure different from the manufacturing method of the present embodiment, in which the shielding core is assembled to a resin-made support portion or the like, as described above, depending on the dimensional tolerance of the shielding core, it may sometimes be impossible to assemble the shielding core to the support portion or the like, and the shielding core has to be discarded. However, in the present embodiment, as described above, by injection molding with the support portion 12 and the shielding core 40 as insert parts, the shielding core 40 at least a part of which is sealed by the core sealing portion 50 is fixed to the support portion 12 via the core sealing portion 50. Therefore, even a shielding core 40 with a large dimensional tolerance can be easily fixed to the support portion 12. Therefore, it is possible to use a shielding core 40 with a large dimensional tolerance, and thus it is possible to suppress an increase in the manufacturing man-hours and the manufacturing cost of the power conversion device 10 and the motor module 1.

[0079] In addition, in a structure different from that of the present embodiment, where the shielding core is assembled to a resin support portion or the like by press-fitting or the like, as described above, burrs are likely to occur in the resin support portion or the like, and the man-hours of such an assembly operation increase. However, in the present embodiment, as described above, by injection molding the support portion 12 and the shielding core 40 as insert parts, the shielding core 40 is fixed to the support portion 12, so that the shielding core 40 can be easily fixed to the support portion 12. Therefore, an increase in the man-hours of the shielding core fixing process Ps can be more appropriately suppressed.

[0080] According to the present embodiment, the support portion 12 has a pair of positioning surfaces 13a, 13b that face each other in the second direction D2, and the shielding core 40 is disposed between the pair of positioning surfaces 13a, 13b. Therefore, in the forming step S2, it is possible to suppress the movement of each shielding core 40 in the second direction D2 due to the pressure received from the resin flowing into the interior of the mold 80. Therefore, the positional accuracy of each shielding core 40 with respect to the support portion 12 can be improved, and thus the positional accuracy of each shielding core 40 with respect to each sensor 25 and each bus bar 30 can be improved. Therefore, the accuracy of each sensor 25 detecting the current value flowing through the bus bar 30 can be more appropriately improved.

[0081] According to the present embodiment, as Figure 4 shown, in the first direction D1, a gap is provided between each of the pair of positioning surfaces 13a, 13b and the inner side surface of the accommodating portion 12c. Therefore, in the forming step S2, the molten resin MR can flow stably toward both sides in the second direction D2 through this gap. In addition, in the present embodiment, a gap is provided between each shielding core 40 and the inner side surface of the accommodating portion 12c in the first direction D1. Therefore, it is easy for the molten resin MR to flow between the shielding core 40 and the inner side surface of the accommodating portion 12c in the second direction D2. Therefore, in the forming step S2, the molten resin MR can be stably filled into the entire interior of the accommodating portion 12c, and thus a part of the shielding core 40 can be stably sealed by the core sealing portion 50. In addition, the contact area between the core sealing portion 50 and the inner side surface of the accommodating portion 12c can be stabilized, so that the core sealing portion 50 can be firmly fixed to the support portion 12. Therefore, each shielding core 40 can be firmly fixed to the support portion 12, so that the positional accuracy of each shielding core 40 with respect to each sensor 25 and each bus bar 30 can be stabilized, and the accuracy of each sensor 25 detecting the current value flowing through the bus bar 30 can be more appropriately improved.

[0082] In addition, in the present embodiment, as described above, in the forming step S2, the injection pressure for causing the molten resin MR to flow into the mold 80 is a low pressure of 0.5 MPa to 15.0 MPa. Therefore, the load applied to the shielding core 40 can be reduced by the resin flowing into the interior of the mold 80. As a result, the change in the magnetic characteristics of the shielding core 40 can be suppressed, and thus the intensity of the magnetic field collected by the shielding core 40 can be stabilized. Therefore, the accuracy of detecting the current value flowing in the bus bar 30 by each sensor 25 can be more appropriately improved.

[0083] <Modification Example 1>

[0084] Figure 6A FIG. is a plan view showing a part of the power conversion device 210 and the motor module 201 according to Modification Example 1 of the above-described first embodiment. Figure 6B FIG. is a cross-sectional view showing the power conversion device 210 according to Modification Example 1 of the first embodiment. In the following description, the same reference numerals are given to the components of the same scheme as those in the above-described first embodiment, and the description thereof is omitted.

[0085] As Figure 6B shown, in the present modification, the accommodating portion is not provided in the support portion 212, and the upper surface 212a of the support portion 212 facing the upper side (-D3 side) is a planar shape extending in a direction orthogonal to the third direction D3. The surface of the first wall portion 40a of each shielding core 40 facing the lower side (+D3 side) is in contact with the upper surface 212a. In the present modification, the upper surface 212a faces the upper side, that is, the other side of the third direction D3, and serves as the support surface 212d in contact with the shielding core 40.

[0086] As Figure 6A and Figure 6B shown, the core sealing portion 250 of the present modification is substantially rectangular parallelepiped-shaped. The core sealing portion 250 seals at least a part of each shielding core 40 with resin. As Figure 6A shown, the core sealing portion 250 covers the entire support surface 212d. As Figure 6B shown, the surface of the core sealing portion 250 facing the lower side is in contact with the support surface 212d. Thus, the core sealing portion 250 is fixed to the support portion 212, and the shielding core 40 is fixed to the support portion 212 via the core sealing portion 250. Therefore, according to the present modification, even a shielding core with large dimensional tolerances can be easily fixed to the support portion 212. As a result, an increase in the manufacturing man-hours and manufacturing costs of the power conversion device 210 and the motor module 201 can be suppressed.

[0087] In addition, in the present modification, in the manufacturing process of the support portion 212, there is no need to provide the accommodating portion, so the manufacturing man-hours of the support portion 212 can be reduced.

[0088] In this modification example, the support portion 212 is connected to the bottom wall portion 211a of the housing 211. That is, the support portion 212 is a part of the housing 211. Therefore, according to this modification example, compared with the case where the support portion 212 is separately provided from the housing 211 and the support portion 212 is fixed to the housing 211 by screws or the like, an increase in the manufacturing man-hours and the number of components of the power conversion device 210 can be suppressed.

[0089] <Modification Example 2>

[0090] Figure 7A It is a top view showing a part of the power conversion device 310 and the motor module 301 according to Modification Example 2 of the above-described first embodiment. Figure 7B It is a cross-sectional view showing the power conversion device 310 according to Modification Example 2 of the first embodiment. In the following description, the same reference numerals are given to the components of the same scheme as those in the above-described first embodiment, and the description thereof is omitted.

[0091] As Figure 7A and Figure 7B shown, the core sealing portion 350 of this modification example resin-seals at least a part of each of the plurality of shield cores 40. The core sealing portion 350 is in contact with the inner side surface of the accommodating portion 12c and is fixed to the support portion 12. Thus, each shield core 40 is fixed to the support portion 12 via the core sealing portion 350. In this modification example, a cutout portion 350a is provided in the core sealing portion 350.

[0092] The cutout portion 350a is provided in a portion between the shield cores 40 adjacent to each other in the second direction D2 in the core sealing portion 350. That is, the cutout portion 350a is provided in a portion between the plurality of shield cores 40 in the core sealing portion 350. In this modification example, the cutout portion 350a is provided by forming the shape of the inner side surface of the mold used in the above-described shield core fixing process Ps to be a shape corresponding to the shape of the cutout portion 350a. In this modification example, the cutout portion 350a is composed of a first cutout portion 350b and a second cutout portion 350c.

[0093] As Figure 7A shown, the first cutout portion 350b is a portion on the rear side (+D1 side) in the cutout portion 350a. As Figure 7B shown, the first cutout portion 350b is recessed from the upper side (-D3 side) facing surface of the core sealing portion 350 downward, that is, toward the side in the third direction D3 (+D3 side).

[0094] As Figure 7AAs shown, the second cut portion 350c is a portion on the front side (-D1 side) in the cut portion 350a. The second cut portion 350c is connected to the first cut portion 350b in the first direction D1. The second cut portion 350c is recessed from the front-facing side of the core seal portion 350 toward the rear side, that is, the +D1 side of the first direction D1. The lower end of the second cut portion 350c is connected to the lower-facing side of the core seal portion 350.

[0095] According to this modification example, a second cut portion (cut portion) 350c recessed in the first direction D1 and a first cut portion (cut portion) 350b recessed in the third direction D3 are provided in the portion between the plurality of shielding cores 40 in the core seal portion 350. Therefore, the volume of the core seal portion 350 can be reduced, and thus the material cost of the resin constituting the core seal portion 350 can be suppressed. Therefore, the manufacturing cost of the power conversion device 310 and the motor module 301 can be suppressed.

[0096] In addition, the shape of the cut portion is not limited to the shape of this modification example. For example, the first cut portion recessed in the third direction D3 may be provided on the front side (-D1 side) of the second cut portion recessed in the first direction D1. Alternatively, one of the first cut portion and the second cut portion may not be provided. In this case, the cut portion is recessed in either the first direction D1 or the third direction D3.

[0097] <Modification Example 3>

[0098] Figure 8A It is a top view showing a part of the power conversion device 410 and the motor module 401 of Modification Example 3 of the above-described first embodiment. Figure 8B It is a cross-sectional view showing the power conversion device 410 of Modification Example 3 of the first embodiment. In the following description, the same reference numerals are given to the components in the same manner as in the above-described first embodiment, and the description thereof is omitted.

[0099] As Figure 8A and Figure 8BAs shown, the core sealing portion 450 of this modification seals at least a part of each of the plurality of shielding cores 40 with resin. The core sealing portion 450 is in contact with the inner side surface and the upper surface 12a of the accommodating portion 12c, and is fixed to the support portion 12. Thus, each shielding core 40 is fixed to the support portion 12 via the core sealing portion 450. The core sealing portion 450 of this modification is composed of a first portion 450a, a second portion 450b, a plurality of third portions 450c, and a plurality of fourth portions 450d. In addition, in the following description, the surface of the second wall portion 40b of each shielding core 40 facing the left side (+D2 side) is referred to as the outer side surface of the second wall portion 40b, and the surface of the third wall portion 40c of each shielding core 40 facing the right side (-D2 side) is referred to as the outer side surface of the third wall portion 40c. In addition, the surface of the second wall portion 40b of each shielding core 40 facing the right side is referred to as the inner side surface of the second wall portion 40b, and the surface of the third wall portion 40c of each shielding core 40 facing the left side is referred to as the inner side surface of the third wall portion 40c. The outer side surfaces of the second wall portion 40b and the third wall portion 40c of each shielding core 40 are the outer side surfaces of each shielding core 40. The inner side surfaces of the second wall portion 40b and the third wall portion 40c of each shielding core 40 are the inner side surfaces of each shielding core 40.

[0100] As Figure 8B shown, the first portion 450a is the portion of the core sealing portion 450 located to the left of the outer side surface of the second wall portion 40b of the shielding core 40D arranged on the leftmost side (+D2 side). The position of the upper side (-D3 side) end portion of the first portion 450a is the same as the position of the upper side end portion of the second wall portion 40b. The first portion 450a is in contact with the entire outer side surface of the second wall portion 40b of the shielding core 40D. That is, the first portion 450a is in contact with the outer side surface of the shielding core 40D.

[0101] As Figure 8B shown, the second portion 450b is the portion of the core sealing portion 450 located to the right of the outer side surface of the third wall portion 40c of the shielding core 40E arranged on the rightmost side (-D2 side). In the third direction D3, the position of the upper side (-D3 side) end portion of the second portion 450b is the same as the position of the upper side end portion of the third wall portion 40c. The second portion 450b is in contact with the entire outer side surface of the third wall portion 40c of the shielding core 40E. That is, the second portion 450b is in contact with the outer side surface of the shielding core 40E.

[0102] As Figure 8BAs shown, the multiple third portions 450c are respectively the portions in the core sealing portion 450 that are between the shielding cores 40 adjacent to each other in the second direction D2. In this modification example, two third portions 450c are provided. In the third direction D3, the positions of the upper (-D3 side) ends of the respective third portions 450c are the same as the positions of the upper ends of the second wall portion 40b and the upper ends of the third wall portion 40c. One third portion 450c contacts the entire outer side surface of the third wall portion 40c of the shielding core 40D and the entire outer side surface of the second wall portion 40b of the shielding core 40F arranged adjacent to the shielding core 40D in the second direction D2. In addition, the other third portion 450c contacts the entire outer side surface of the third wall portion 40c of the shielding core 40F and the entire outer side surface of the second wall portion 40b of the shielding core 40E. That is, the multiple third portions 450c contact the outer side surfaces of the shielding cores 40.

[0103] As Figure 8B shown, the multiple fourth portions 450d are respectively the portions located between the outer side surface of the second wall portion 40b and the outer side surface of the third wall portion 40c of each shielding core 40. In this modification example, three fourth portions 450d are provided. In the third direction D3, the positions of the upper (-D3 side) ends of the respective fourth portions 450d are located lower (+D3 side) than the positions of the upper ends of the second wall portion 40b and the upper ends of the third wall portion 40c. Each fourth portion 450d is arranged lower than the bus bar 30. Therefore, the upper ends of the first portion 450a, the second portion 450b, and the third portion 450c are located higher than the upper ends of the fourth portion 450d. Each fourth portion 450d contacts the lower portions of the inner side surface of the second wall portion 40b and the lower portions of the inner side surface of the third wall portion 40c of each shielding core 40. That is, the multiple fourth portions 450d contact the inner side surfaces of the shielding cores 40.

[0104] Therefore, according to this modification example, the portions in the core sealing portion 450 that contact the outer side surfaces of the multiple shielding cores 40, namely the upper sides of the first portion 450a, the second portion 450b, and the third portion 450c, that is, the ends on the other side (-D3 side) in the third direction D3, are located higher than the upper ends of the fourth portion 450d that contacts the inner side surfaces of the multiple shielding cores 40. Therefore, the area where each shielding core 40 contacts the air can be reduced, and thus rusting of the shielding core 40 due to moisture or the like contained in the air can be suppressed. Therefore, variation in the magnetic characteristics of the shielding core 40 can be suppressed, and thus the intensity of the magnetic field collected by the shielding core 40 can be stabilized. Therefore, the accuracy of the current value detected by each sensor 25 flowing through each bus bar 30 can be stabilized.

[0105] <Modification Example 4>

[0106] Figure 9A It is a top view showing a part of the power conversion device 510 and the motor module 501 according to Modification Example 4 of the above-described first embodiment. Figure 9B It is a cross-sectional view showing the power conversion device 510 according to Modification Example 4 of the first embodiment. In the following description, the components of the same scheme as those of the above-described first embodiment are denoted by the same reference numerals, and their descriptions are omitted.

[0107] As Figure 9B shown, in this modification, the first wall portion 40a of each shielding core 40 and the support surface 12d are arranged at intervals in the third direction D3. In addition, the second wall portion 40b and the third wall portion 40c of each shielding core 40 are respectively arranged at intervals in the second direction D2 with respect to a pair of positioning surfaces 13a, 13b. That is, each shielding core 40 is arranged at an interval from the support portion 12.

[0108] According to this modification, the first wall portion 40a can be fixed to the support surface 12d via the portion of the core sealing portion 550 that is located between the first wall portion 40a of each shielding core 40 and the support surface 12d of the support portion 12 in the third direction D3. Therefore, each shielding core 40 can be more firmly fixed to the support portion 12 via the core sealing portion 550, and thus the accuracy of the current value detected by each sensor 25 flowing through each bus bar 30 can be stabilized.

[0109] The present invention is not limited to the above-described embodiments, and other structures and other methods can also be adopted within the scope of the technical idea of the present invention.

[0110] The use of the power conversion device of the present embodiment is not limited to generating power supplied to the motor for driving a vehicle, and it can also generate power supplied to the motor mounted on an electrical appliance or the like. In addition, the power conversion device can be an inverter that generates an alternating current of a predetermined waveform based on a direct current supplied from an external power source, or a converter that generates a direct current based on an alternating current supplied from an external power source.

[0111] As long as the position of the shielding core relative to the support portion can be accurately determined, the structure of the support portion is not limited to the structure of the present embodiment. For example, a pair of positioning surfaces may not be provided on the support portion. In this case, a pair of positioning surfaces can be provided on the inner side surface of the mold used in the shielding core fixing process Ps, and the position of the shielding core relative to the support portion can be determined by the pair of positioning surfaces.

[0112] In addition, a part of the bus bar may be buried inside the core sealing portion. In this case, in the shielding core fixing process, the bus bar is injection-molded as a part of the insert member, whereby a part of the bus bar can be buried inside the core sealing portion. In addition, a hole may be provided in the formed core sealing portion, and the bus bar may be passed through the hole.

[0113] The number of each of the bus bar, the sensor, and the shielding core provided in the power conversion device is not limited to three, and may be one or two, or may be four or more.

[0114] In the above-described embodiments and modification examples, the case where the sensor is mounted on the substrate protruding portion that protrudes from the edge portion of the circuit board in one direction, and the substrate protruding portion is disposed between the second wall portion and the third wall portion of the shielding core has been described. However, a pair of hole portions for respectively inserting the second wall portion and the third wall portion of the shielding core may be provided in the circuit board, and the sensor may be mounted between the pair of hole portions.

[0115] The embodiments of the present invention have been described above, but each structure in the embodiments and their combinations and the like are an example, and additions, omissions, replacements, and other changes of the structure can be made without departing from the gist of the present invention. In addition, the present invention is not limited by the embodiments.

[0116] In addition, the present technology may adopt the following structure.

[0117] (1) A power conversion device, comprising: a bus bar extending in a first direction; a sensor that detects a magnetic field generated by a current flowing through the bus bar; a shielding core having magnetism and surrounding the bus bar and the sensor from at least one side in a second direction orthogonal to the first direction and in a third direction orthogonal to the first direction and the second direction; a core sealing portion that seals at least a part of the shielding core with resin; and a support portion, wherein the shielding core is fixed to the support portion via the core sealing portion.

[0118] (2) The power conversion device according to (1), wherein the support portion has a pair of positioning surfaces facing each other in the first direction or the second direction, and the shielding core is disposed between the pair of positioning surfaces.

[0119] (3) The power conversion device according to (2), wherein a receiving portion recessed toward one side in the third direction is provided on a surface of the support portion facing the other side in the third direction, and the core sealing portion is in contact with an inner surface of the receiving portion.

[0120] (4) The power conversion device according to (3), wherein the pair of positioning surfaces face each other in the second direction, and a gap is provided between each of the pair of positioning surfaces and the inner surface of the receiving portion in the first direction.

[0121] (5) The power conversion device according to any one of (1) to (4), wherein the support portion has a support surface facing the other side in the third direction, and the shielding core is in contact with the support surface.

[0122] (6) The power conversion device according to any one of (1) to (4), wherein the shielding core is arranged with a gap from the support portion.

[0123] (7) The power conversion device according to any one of (1) to (6), comprising: a plurality of the bus bars arranged in the second direction; a plurality of the sensors; and a plurality of the shielding cores, wherein the plurality of the shielding cores surround one of the sensors and one of the bus bars from both sides in the second direction and at least one side in the third direction.

[0124] (8) The power conversion device according to (7), wherein the core sealing portion seals a part of each of the plurality of the shielding cores with resin, and a cut portion recessed in the first direction or the third direction is provided in a portion between the plurality of the shielding cores in the core sealing portion.

[0125] (9) The power conversion device according to (7), wherein the core sealing portion seals a part of each of the plurality of the shielding cores with resin, and an end portion on the other side in the third direction of a portion in the core sealing portion that contacts the outer side surfaces of the plurality of the shielding cores is located on the other side in the third direction compared to an end portion on the other side in the third direction of a portion in the core sealing portion that contacts the inner side surfaces of the plurality of the shielding cores.

[0126] (10) The power conversion device according to any one of (1) to (9), wherein the bus bar, the sensor, the shielding core, and the core sealing portion are accommodated in a housing of the power conversion device,

[0127] The support portion is a part of the housing.

[0128] (11) A motor module, comprising: the power conversion device according to any one of (1) to (10); and a motor driven by the power conversion device.

[0129] (12) A method for manufacturing a power conversion device, the power conversion device comprising: a shielding core having magnetism; a core sealing portion made of resin; and a support portion, the method for manufacturing the power conversion device having: a positioning step of determining a position of the shielding core relative to the support portion in a mold; and a molding step of molding the core sealing portion that seals at least a part of the shielding core with resin and is fixed to the support portion by injection molding with the support portion and the shielding core as insert parts.

Claims

1. A power conversion device, characterized in that, it comprises: a bus bar extending in a first direction; a sensor that detects a magnetic field generated by a current flowing through the bus bar; a shielding core having magnetism, surrounding the bus bar and the sensor from both sides in a second direction orthogonal to the first direction and at least one side in a third direction orthogonal to the first direction and the second direction; a core sealing portion that seals at least a part of the shielding core with resin; and a support portion, wherein the shielding core is fixed to the support portion via the core sealing portion.

2. The power conversion device according to claim 1, characterized in that, the support portion has a pair of positioning surfaces facing each other in the first direction or the second direction, and the shielding core is disposed between the pair of positioning surfaces.

3. The power conversion device according to claim 2, characterized in that, a receiving portion recessed toward one side in the third direction is provided on a surface of the support portion facing the other side in the third direction, and the core sealing portion contacts an inner side surface of the receiving portion.

4. The power conversion device according to claim 3, characterized in that, the pair of positioning surfaces face each other in the second direction, and in the first direction, a gap is provided between each of the pair of positioning surfaces and the inner side surface of the receiving portion.

5. The power conversion device according to claim 1, characterized in that, the support portion has a support surface facing the other side in the third direction, and the shielding core contacts the support surface.

6. The power conversion device according to claim 1, characterized in that, the shielding core is disposed with a gap from the support portion.

7. The power conversion device according to any one of claims 1 to 6, characterized in that, it comprises: a plurality of the bus bars arranged and configured in the second direction; a plurality of the sensors; and a plurality of the shielding cores, wherein the plurality of shielding cores respectively surround one sensor and one bus bar from both sides in the second direction and at least one side in the third direction.

8. The power conversion device according to claim 7, characterized in that, the core sealing portion seals a part of each of the plurality of shielding cores with resin, and a cutout portion recessed in the first direction or the third direction is provided in a portion between the plurality of shielding cores in the core sealing portion.

9. The power conversion device according to claim 7, characterized in that, the core sealing portion seals a part of each of the plurality of shielding cores with resin, and an end portion on the other side in the third direction of a portion of the core sealing portion contacting an outer side surface of each of the plurality of shielding cores is located on the other side in the third direction relative to an end portion on the other side in the third direction of a portion of the core sealing portion contacting an inner side surface of each of the plurality of shielding cores.

10. The power conversion device according to any one of claims 1 to 6, characterized in that, the bus bar, the sensor, the shielding core, and the core sealing portion are accommodated in a housing of the power conversion device, and the support portion is a part of the housing.

11. A motor module, characterized in that, Comprising: a power conversion device according to any one of claims 1 to 6; and a motor driven by the power conversion device.

12. A method of manufacturing a power conversion device, the power conversion device comprising: a magnetic shielding core; a resin core sealing portion; and a support portion, The method of manufacturing the power conversion device is characterized by having: a positioning step of determining the position of the shielding core relative to the support portion within a mold; and a forming step of forming the core sealing portion that seals at least a part of the shielding core with resin and is fixed to the support portion by injection molding with the support portion and the shielding core as insert parts.

Images