Power module, outer wall resin for power module, and method for manufacturing power module

Abstract

The invention relates to a power module, an outer wall resin for the power module, and a method for manufacturing the power module. The power module has a bus bar, a magnetic detection unit, and an outer wall resin, the outer wall resin has an insertion hole into which the magnetic detection unit is inserted, and the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit when viewed from the insertion direction of the magnetic detection unit. A method for manufacturing a power module having a bus bar and a magnetic detection unit, the method comprising: a step for resin-molding the bus bar to form an outer wall resin having an insertion hole into which the magnetic detection unit is inserted; and a step of inserting the magnetic detection part into the insertion hole, the insertion hole having a shape corresponding to the outer shape of the magnetic detection part when viewed from an insertion direction in which the magnetic detection part is inserted into the outer wall resin.

Description

Technical Field

[0001] The present invention relates to a power module, an outer wall resin for a power module, and a method for manufacturing a power module. Background Art

[0002] Patent Document 1 discloses "an electrical device that can contribute to the simplification, miniaturization, and shielding effect of the structure of an electrical device". Patent Document 2 discloses "a power module provided with a sensing unit".

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2023-138260

[0006] Patent Document 2: US Patent Publication No. 2022 / 0262773 Summary of the Invention

[0007] In a first aspect of the present invention, there is provided a power module. The power module has a busbar, a magnetic detection unit, and an outer wall resin. The outer wall resin has an insertion hole for inserting the magnetic detection unit. When viewed from the insertion direction of the magnetic detection unit, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit.

[0008] The magnetic detection unit may have a magnetic detection element and a substrate on which the magnetic detection element is fixed. A plane of the substrate having the magnetic detection element may be orthogonal to the insertion direction.

[0009] The magnetic detection unit may have a magnetic detection element and a substrate on which the magnetic detection element is fixed. A plane of the substrate having the magnetic detection element may be parallel to the insertion direction.

[0010] The outer wall resin may cover a part of the busbar.

[0011] In the above power module, three of the busbars may be arranged in a direction orthogonal to the extending direction of the busbar.

[0012] The power module may have one of the busbars.

[0013] The magnetic detection unit may have a magnetic detection element, an element portion on which the magnetic detection element is fixed, and a substrate on which the element portion is fixed. A part of a wall surface of the outer wall resin forming the insertion hole may have a positioning portion that contacts the element portion.

[0014] The above magnetic detection unit is inserted into the above insertion hole, and there may be a gap between the wall surface of the insertion hole formed by the above outer wall resin and the side surface of the above magnetic detection unit.

[0015] The above magnetic detection unit may be fixed in the above insertion hole in a state where there is a gap between the wall surface of the insertion hole formed by the above outer wall resin and the side surface of the above magnetic detection unit.

[0016] The above magnetic detection unit is inserted into the above insertion hole, and the lower surface of the wall surface of the insertion hole formed by the above outer wall resin may be in contact with the lower end of the above magnetic detection unit.

[0017] The above magnetic detection unit may have a magnetic detection element and a substrate on which the magnetic detection element is fixed. The above magnetic detection unit is inserted into the above insertion hole, and a part of the wall surface of the insertion hole formed by the above outer wall resin may be in contact with the lower surface of the above substrate.

[0018] The above outer wall resin may have a first part surrounding at least a part of the above bus bar and a second part provided with the above insertion hole.

[0019] The above bus bar may not be exposed in the above insertion hole.

[0020] The surface of the above insertion hole orthogonal to the above insertion direction may have a shape complementary to the outer shape of the above magnetic detection unit.

[0021] In the second aspect of the present invention, there is provided an outer wall resin for a power module. The outer wall resin for a power module is an outer wall resin for a power module having a bus bar and a magnetic detection unit. Among them, the outer wall resin for a power module has an insertion hole for inserting the above magnetic detection unit. When viewed from the insertion direction of the above magnetic detection unit, the above insertion hole has a shape corresponding to the outer shape of the above magnetic detection unit.

[0022] In the third aspect of the present invention, there is provided a method for manufacturing a power module. The method for manufacturing a power module is a method for manufacturing a power module having a bus bar and a magnetic detection unit. Among them, the method for manufacturing a power module has the following steps: a step of resin-molding the above bus bar to form an outer wall resin having an insertion hole for inserting the above magnetic detection unit; and a step of inserting the above magnetic detection unit into the above insertion hole. When viewed from the insertion direction of inserting the above magnetic detection unit into the above outer wall resin, the above insertion hole has a shape corresponding to the outer shape of the above magnetic detection unit.

[0023] It should be noted that the above description of the invention does not list all the features of the present invention. In addition, sub-combinations of these feature groups can also form inventions. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1A perspective view showing an example of the schematic structure of the power module 101 of the first embodiment.

[0025] Figure 2 A perspective view showing an example of the schematic structure of the bus bar 20 of the first embodiment, the second embodiment, the third embodiment, and the fourth embodiment.

[0026] Figure 3 A perspective view showing an example of the schematic structure of the magnetic detection unit 30 of the first embodiment.

[0027] Figure 4 An exploded perspective view showing an example of the schematic structure of the power module 101 of the first embodiment.

[0028] Figure 5 A first example of a top view showing the schematic structure of the insertion hole 11 of the first embodiment.

[0029] Figure 6 A first example of a side cross-sectional view showing the schematic structure of the insertion hole 11 of the first embodiment.

[0030] Figure 7 A second example of a side cross-sectional view showing the schematic structure of the insertion hole 11 of the first embodiment.

[0031] Figure 8 A perspective view showing an example of the schematic structure of the power module 102 of the second embodiment.

[0032] Figure 9 A perspective view showing an example of the schematic structure of the magnetic detection unit 30a of the second embodiment.

[0033] Figure 10 An exploded perspective view showing an example of the schematic structure of the power module 102 of the second embodiment.

[0034] Figure 11 A top view showing the schematic structure of the insertion hole 11 of the second embodiment.

[0035] Figure 12 A side cross-sectional view showing the schematic structure of the insertion hole 11 of the second embodiment.

[0036] Figure 13 A perspective view showing an example of the schematic structure of the power module 103 of the third embodiment.

[0037] Figure 14 A perspective view showing an example of the schematic structure of the power module 104 of the fourth embodiment.

[0038] Figure 15A perspective view showing an example of the schematic structure of the power module 105 according to the fifth embodiment.

[0039] Figure 16 A side sectional view showing the schematic structure of the power module 105 according to the fifth embodiment.

[0040] Figure 17 Another example of a side sectional view showing the schematic structure of the power module 105 according to the fifth embodiment.

[0041] Figure 18 A perspective view showing an example of the schematic structure of the power module 106 according to the sixth embodiment.

[0042] Figure 19 A side sectional view showing the schematic structure of the power module 106 according to the sixth embodiment.

[0043] Figure 20 Another example of a side sectional view showing the schematic structure of the power module 106 according to the sixth embodiment.

[0044] Figure 21 A perspective view showing an example of the schematic structure of the power module 107 according to the seventh embodiment.

[0045] Figure 22 A perspective view showing an example of the schematic structure of the power module 108 according to the eighth embodiment.

[0046] Figure 23 An explanatory diagram showing a part of the manufacturing process of the power module 101 according to the first embodiment.

[0047] Figure 24 An explanatory diagram showing a part of the manufacturing process of the power module 101 according to the first embodiment.

[0048] Figure 25 An explanatory diagram showing a part of the manufacturing process of the power module 101 according to the first embodiment.

[0049] Figure 26 An explanatory diagram showing a part of the manufacturing process of the power module 102 according to the second embodiment.

[0050] Figure 27 An explanatory diagram showing a part of the manufacturing process of the power module 102 according to the second embodiment.

[0051] Figure 28 An explanatory diagram showing a part of the manufacturing process of the power module 102 according to the second embodiment.

[0052] Figure 29A perspective view showing an example of a schematic structure of a modified example of the bus bar 20.

[0053] Figure 30 A perspective view showing an example of a schematic structure of a modified example of the bus bar 20.

[0054] Reference numeral description

[0055] 10 Outer wall resin, 11 Insertion hole, 11a Bottom surface, 12 Adhesive, 13 Positioning portion, 14 Gap, 15 Concave portion, 16 First portion, 17 Second portion, 18 Injection hole, 20 Bus bar, 20a Bus bar, 20c Other bus bar, 21 Main body portion, 22 Main body portion, 23 Current path, 24 Current path, 25 Through hole, 26 Notch portion, 27 Current path, 30 Magnetic detection portion, 30a Magnetic detection portion, 31 Substrate, 32 Element portion, 33 Connection terminal, 34 Magnetic detection element, 35 Magnetic detection element, 40 Protection resin, 101 - 108 Power modules Detailed implementation manners

[0056] Hereinafter, the present invention will be described by way of embodiments of the invention. However, the following embodiments do not limit the invention described in the claims. In addition, the combinations of the features described in the embodiments are not necessarily all essential for the solution means of the invention.

[0057] Figure 1 A perspective view showing an example of the schematic structure of the power module 101 in the first embodiment. The xyz coordinate system is shown in each figure. As Figure 1 shown, the power module 101 has an outer wall resin 10, a bus bar 20 protruding toward the -y direction side, a magnetic detection portion 30, a protection resin 40, and two other bus bars 20c protruding toward the +y direction side. The power module 101 of the first embodiment is a single-phase power module. The outer wall resin 10 forms the outer wall of the power module 101 and is formed to cover the power module 101. It should be noted that the bus bar 20 is a conductor for the inflow and outflow of current from the outside and also serves as a conductor for measuring current. That is, when the bus bar 20 is assembled into the power module 101, it can be a conductor through which the current to be measured flows. In addition, the bus bar 20c serves as a conductor for connecting to a battery. The protection resin 40 is provided to protect the components inside the power module 101. As the protection resin 40, for example, a gel-like resin such as silicone resin or an epoxy resin is used.

[0058] Figure 2 A perspective view showing an example of the schematic structure of the bus bar 20 in the first embodiment. The bus bar 20 has two main body portions 21, 22, two current paths 23, 24, and a through hole 25. It should be noted that Figure 2The bus bar 20 shown is also used in the second embodiment, the third embodiment, and the fourth embodiment.

[0059] As Figure 2 shown, two main body portions 21 and 22 are arranged in the y-direction. Two current paths 23 and 24 are arranged between the two main body portions 21 and 22 and extend in parallel with each other to connect the two main body portions 21 and 22. A through hole 25 is arranged between the two current paths 23 and 24. Measured currents flow in the same direction in the two current paths 23 and 24 respectively. In this embodiment, the two current paths 23 and 24 are conductors with a rectangular cross-sectional shape and extending linearly. It should be noted that the cross-sectional shape of the two current paths 23 and 24 can also be any shape such as circular or elliptical. Similarly, the shape of the main body portion 22 is rectangular in the drawings, but it can also be freely deformed according to the structure of the power module 101.

[0060] Figure 3 FIG. is a perspective view showing an example of the schematic structure of the magnetic detection unit 30 in the first embodiment. The magnetic detection unit 30 has a substrate 31, an element portion 32, and connection terminals 33. For example, two magnetic detection elements 34 and 35 are molded and fixed on the element portion 32 with resin. The element portion 32 can be, for example, a magnetic sensor. It should be noted that the number of magnetic detection elements included in the element portion 32 is not limited to two. For example, the element portion 32 can have only one magnetic detection element, or can have more than two magnetic detection elements. In addition, the number, arrangement, etc. of the magnetic detection elements are not limited to the illustrated manner.

[0061] When the element portion 32 has two magnetic detection elements 34 and 35, the two magnetic detection elements 34 and 35 respectively detect the intensity of the magnetic fields generated on the respective magnetic sensing surfaces by the measured currents flowing in the y-direction in the two current paths 23 and 24, and output detection signals corresponding to the detection intensities respectively detected by the two magnetic detection elements 34 and 35. The two magnetic detection elements 34 and 35 are respectively arranged in such a way that the magnetic fields generated by the measured currents flowing in the same direction in the two current paths 23 and 24 penetrate the magnetic sensing surfaces. In order to suppress interference magnetic fields, increase output signals, eliminate offsets, etc., multiple magnetic detection elements can also be arranged.

[0062] When the element portion 32 is a magnetic sensor, it can include one or more than two magnetic detection elements, a signal processing IC that processes the output signal based on the detection signal output from the magnetic detection element, an output terminal that outputs the output signal, and a package that seals a part of the magnetic detection element, the signal processing IC, and the output terminal.

[0063] As a magnetic detection element, a magnetoelectric conversion element can be used. As the magnetoelectric conversion element, for example, a Hall element that obtains a detection signal proportional to the magnitude of the magnetic flux density can be used. It should be noted that as the magnetoelectric conversion element, in addition to the Hall element, a magnetoresistive element, a magneto-impedance element, etc. can also be used. In addition, as long as it is a magnetic sensor IC such as a magnetic sensor IC formed by combining these magnetoelectric conversion elements and an IC processing circuit, and the detection signal is uniquely determined with respect to the applied magnetic flux density, it can be used as a magnetic detection element. When a plurality of magnetic detection elements are arranged, their shapes and sizes can be different. When two magnetic detection elements are arranged, the shapes and sizes of the magnetic detection elements 34 and 35 can be different.

[0064] Figure 4 FIG. 4 is an exploded perspective view showing an example of the schematic structure of the power module 101 in the first embodiment. It should be noted that Figure 4 only depicts the structure on the front side (-y direction side) of the power module 101, and does not depict the structure on the inner side (+y direction side), such as the protective resin 40, etc. As Figure 4 shown, the outer wall resin 10 of the power module 101 has an insertion hole 11 for inserting the magnetic detection unit 30. The surface of the substrate 31 having the element portion 32 is parallel to the insertion direction (z direction) of the magnetic detection unit 30.

[0065] Figure 5 FIG. 12 is a first example of a top view showing the schematic structure of the insertion hole 11 in the first embodiment. Figure 5 FIG. 14 shows a view when observed from the insertion direction (z direction) of the magnetic detection unit 30. As Figure 5 shown, when observed from the insertion direction of the magnetic detection unit 30, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection unit 30. The "shape corresponding to the outer shape" of the magnetic detection unit 30 refers to the shape corresponding to the shape of the projection plane of the magnetic detection unit 30 in the z direction. It can also be said that they are complementary shapes in the direction orthogonal to the insertion direction. For example, when the shape of the projection plane of the magnetic detection unit 30 in the z direction is a right convex shape as Figure 5 shown, the shape of the insertion hole 11 is a right convex shape. In addition, the "corresponding shape" is not the same shape, but a shape that is one size larger, so that the magnetic detection unit 30 can be inserted into the insertion hole 11.

[0066] Figure 6FIG. 0 is a first example of a side cross-sectional view showing a schematic structure of the insertion hole 11 in the first embodiment. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the lower end portion of the substrate 31 of the magnetic detection unit 30, thereby positioning the magnetic detection unit 30 in the vertical direction. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed to the inside of the insertion hole 11 by an adhesive 12. It should be noted that in a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the power module 101 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30. The current paths 23 and 24 of the bus bar 20 are arranged inside the outer wall resin 10. That is, the bus bar 20a is not exposed on the surface of the wall surface of the outer wall resin 10 forming the insertion hole 11.

[0067] Figure 7 FIG. 4 is a second example of a side cross-sectional view showing a schematic structure of the insertion hole 11 in the first embodiment. A part of the wall surface of the outer wall resin 10 forming the insertion hole 11 has a positioning portion 13 that contacts the element portions 32 of the magnetic detection elements 34 and 35 fixed thereto. The positioning portion 13 is formed based on the shapes of the substrate 31 and the element portion 32, and is a portion that protrudes toward the center of the insertion hole 11 and contacts the element portion 32 in the wall surface of the outer wall resin 10 forming the insertion hole 11 in a state where the magnetic detection unit 30 is inserted into the insertion hole 11. That is, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the lower end portion of the substrate 31 of the magnetic detection unit 30, and the lower portion of the element portion 32 contacts the positioning portion 13. Thereby, the magnetic detection unit 30 is positioned in the vertical direction. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed to the inside of the insertion hole 11 by an adhesive 12. It should be noted that in a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the power module 101 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30. The current paths 23 and 24 of the bus bar 20 are arranged inside the outer wall resin 10. That is, the bus bar 20a is not exposed on the surface of the wall surface of the outer wall resin forming the insertion hole 11.

[0068] Figure 8 FIG. 8 is a perspective view showing an example of a schematic structure of the power module 102 in the second embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and description thereof is omitted. As Figure 8 shown, the power module 102 has an outer wall resin 10, a bus bar 20 protruding toward the -y direction side, a magnetic detection unit 30a, a protective resin 40, and another bus bar 20c protruding toward the +y direction side. The power module 102 in the second embodiment is a single-phase power module.

[0069] Figure 9 A perspective view showing an example of the schematic structure of the magnetic detection unit 30a in the second embodiment. The magnetic detection unit 30a includes a substrate 31, an element portion 32, and connection terminals 33. On the element portion 32, for example, two magnetic detection elements 34, 35 are molded and fixed with resin. The element portion 32 can be, for example, a magnetic sensor. The magnetic detection unit 30a in the second embodiment is different from the magnetic detection unit 30 in the first embodiment in that the substrate 31 is a plane parallel to the xy plane. The element portion 32 is provided on the lower surface (-z direction side surface) of the substrate 31.

[0070] Figure 10 An exploded perspective view showing an example of the schematic structure of the power module 102 in the second embodiment. As Figure 10 shown, the outer wall resin 10 of the power module 102 has an insertion hole 11 for inserting the magnetic detection unit 30a. It should be noted that in Figure 10 , only the structure of the front side (-y direction side) of the power module 102 is depicted, and the protective resin 40 etc. on the inner side (+y direction side) are not depicted. The surface (xy plane) of the substrate 31 having the element portion 32 is orthogonal to the insertion direction (z direction) of the magnetic detection unit 30a.

[0071] Figure 11 A top view showing the schematic structure of the insertion hole 11 in the second embodiment. Figure 11 A view showing the magnetic detection unit 30a when observed from the insertion direction (z direction). As Figure 11 shown, when observed from the insertion direction (z direction) of the magnetic detection unit 30a, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection unit 30a. That is, since the shape of the projection plane of the magnetic detection unit 30a in the z direction is rectangular, the shape of the insertion hole 11 when observed from the z direction is rectangular. A concave portion 15 for arranging the element portion 32 protruding in the -z direction is provided in the central portion of the insertion hole 11.

[0072] Figure 12 A side cross-sectional view showing the schematic structure of the insertion hole 11 in the second embodiment. As Figure 12 shown, in Figure 12When viewed from the y-direction as described above, the outer shape of the magnetic detection unit 30a is a downwardly convex shape, and thus the shape of the insertion hole 11 is a downwardly convex shape. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, a part of the wall surface of the outer wall resin 10 forming the insertion hole 11 contacts the lower end portion of the substrate 31 of the magnetic detection unit 30a. Thereby, the magnetic detection unit 30a is positioned in the vertical direction. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30a is fixed in the insertion hole 11 using an adhesive 12. It should be noted that the magnetic detection unit 30a of the power module 102 is inserted into the insertion hole 11, and there is a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the substrate 31 of the magnetic detection unit 30a. In addition, the current paths 23, 24 of the bus bar 20 are arranged inside the outer wall resin 10. The lower surface of the element portion 32 may contact the wall surface of the outer wall resin 10 forming the recess 15, or there may be a gap between the element portion 32 and the wall surface of the outer wall resin 10 forming the recess 15.

[0073] Figure 13 FIG. is a perspective view showing an example of the schematic structure of the power module 103 in the third embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and description thereof is omitted. The power module 103 in the third embodiment is a power module for a three-phase motor and includes three bus bars 20 arranged in a row along the x-direction.

[0074] The three bus bars 20 respectively correspond to the U-phase, V-phase, and W-phase in the three-phase alternating current.

[0075] As Figure 13 shown, the power module 103 has an outer wall resin 10, three bus bars 20 protruding toward the -y direction side, three magnetic detection units 30, a protective resin 40, and another bus bar 20c protruding toward the +y direction side. The three magnetic detection units 30 are each the same as the magnetic detection unit 30 shown in Figure 3 shown, and the three bus bars 20 are each the same as the bus bar 20 shown in Figure 2 shown. The outer wall resin 10 of the power module 103 has three insertion holes 11 for inserting the three magnetic detection units 30. When viewed from the insertion direction of the three magnetic detection units 30, the three insertion holes 11 have shapes corresponding to the outer shapes of the three magnetic detection units 30. The shapes of the 3 insertion holes 11 are the same as the shapes shown in Figure 5 and Figure 6 shown.

[0076] Figure 14A perspective view showing an example of the schematic structure of the power module 104 in the fourth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and their description is omitted. The power module 104 in the fourth embodiment is a power module for a three-phase motor and includes three buses 20 in the first embodiment, and the three buses 20 are arranged in the x direction.

[0077] The three buses 20 respectively correspond to the U phase, V phase, and W phase in the three-phase alternating current.

[0078] As Figure 14 shown, the power module 104 has an outer wall resin 10, three buses 20 protruding toward the -y direction side, three magnetic detection parts 30a, a protective resin 40, and another bus 20c protruding toward the +y direction side. The three magnetic detection parts 30a are each the same as the magnetic detection part 30a Figure 9 shown. The outer wall resin 10 of the power module 104 has three insertion holes 11 for inserting the three magnetic detection parts 30a. When viewed from the insertion direction of the three magnetic detection parts 30a, the three insertion holes 11 have a shape corresponding to the outer shape of the three magnetic detection parts 30a. The shapes of the 3 insertion holes 11 are the same as Figure 10 and Figure 11 shown.

[0079] Figure 15 A perspective view showing an example of the schematic structure of the power module 105 in the fifth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and their description is omitted. As Figure 15 shown, the power module 105 has an outer wall resin 10, a bus 20a protruding toward the -y direction side, a current path 27 connected to the bus 20a, a magnetic detection part 30, a protective resin 40, and another bus 20c protruding toward the +y direction side. The current path 27 is connected to the bus 20a by screw fixation, welding, or other methods. The power module 105 in the fifth embodiment is a power module for single-phase use. The magnetic detection part 30 is the same as the magnetic detection part 30 Figure 3 shown, and the insertion hole 11 for inserting the magnetic detection part 30 is the same as the insertion hole 11 Figure 4 and Figure 5 shown. Since the protective resin 40 is disposed inside the power module 105, it will be described in the part Figure 16 .

[0080] Figure 16 A side cross-sectional view showing an example of the schematic structure of the power module 105 in the fifth embodiment. As Figure 16As shown, the outer wall resin 10 has a first portion 16 that surrounds at least a part of the current path 27 and the protective resin 40, and a second portion 17 provided with an insertion hole 11. The first portion 16 has a protruding portion 16a that supports the second portion 17 from below. In this example, the first portion 16 and the second portion 17 are molded separately. An insertion hole 11 is provided in the second portion 17 for inserting the magnetic detection unit 30. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the lower end portion of the substrate 31 of the magnetic detection unit 30 and is positioned. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed to the insertion hole 11 by an adhesive 12. It should be noted that in a state where the magnetic detection unit 30 is inserted into the insertion hole 11, there is a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30 in the power module 105. A part of the bus bar 20a and the current path 27 connected to the bus bar 20a are covered by the protective resin 40.

[0081] Figure 17 Another example of a side cross-sectional view showing a schematic structure of the power module 105 in the fifth embodiment. As Figure 17 shown, the outer wall resin 10 has a first portion 16 that surrounds at least a part of the current path 27 and a second portion 17 provided with an insertion hole 11. In another example, the first portion 16 and the second portion 17 are integrally molded. Therefore, in Figure 17 it, the first portion 16 and the second portion 17 are represented by the same shading. An insertion hole 11 is provided in the second portion 17 forming the cover for inserting the magnetic detection unit 30. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the lower surface of the substrate 31 of the magnetic detection unit 30 and is positioned. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed to the insertion hole 11 by an adhesive 12. An injection hole 18 for injecting the protective resin 40 is provided in the upper part of the current path 27 connected to the bus bar 20a, and the current path 27 is covered by the protective resin 40.

[0082] Figure 18 A perspective view showing an example of a schematic structure of the power module 106 in the sixth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and description thereof is omitted. As Figure 18As shown, the power module 106 has an outer wall resin 10, a bus bar 20a protruding toward the -y direction side, a current path 27 connected to the bus bar 20a, a magnetic detection unit 30a, and another bus bar 20c protruding toward the +y direction side. The power module 106 in the sixth embodiment is a single-phase power module. The magnetic detection unit 30a is the same as Figure 9 the magnetic detection unit 30a shown. The bus bar 20a in this embodiment is the same as the bus bar 20a in the fifth embodiment.

[0083] Figure 19 FIG. is a side cross-sectional view schematically showing the power module 106 in the sixth embodiment. As Figure 19 shown, the outer wall resin 10 has a first part 16 surrounding at least a part of the current path 27 and the protective resin 40, and a second part 17 provided with an insertion hole 11. In this example, the first part 16 and the second part 17 are formed separately. An insertion hole 11 is provided in the second part 17 for inserting the magnetic detection unit 30a. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the substrate 31 of the magnetic detection unit 30a and is positioned. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30a is fixed to the insertion hole 11 by an adhesive 12. A part of the bus bar 20a and the current path 27 connected to the bus bar 20a are covered with the protective resin 40.

[0084] Figure 20 FIG. is another example of a side cross-sectional view schematically showing the power module 106 in the sixth embodiment. As Figure 20 shown, the outer wall resin 10 has a first part 16 surrounding at least a part of the current path 27 and the protective resin 40, and a second part 17 provided with an insertion hole 11. In another example, the first part 16 and the second part 17 are integrally formed. Therefore, in Figure 20 FIG., the first part 16 and the second part 17 are shown with the same shading. An insertion hole 11 is provided in the second part 17 forming the cover for inserting the magnetic detection unit 30a. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 contacts the substrate 31 of the magnetic detection unit 30a and is positioned. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed to the insertion hole 11 by an adhesive 12. An injection hole 18 for injecting the protective resin 40 is provided above the current path 27 connected to the bus bar 20a, and the current path 27 is covered with the protective resin 40.

[0085] In the fifth and sixth embodiments, when the element section 32 has two magnetic detection elements 34 and 35, the magnetic detection elements 34 and 35 respectively detect the intensity of the magnetic field generated due to the measured current flowing through the current path 27 on each magnetic sensing surface, and output detection signals corresponding to the detection intensities detected by the two magnetic detection elements 34 and 35 respectively. In this case, in one example, the shape of the bus bar 20a may also be a rectangle composed only of the main body portion.

[0086] Figure 21 FIG. is a perspective view showing an example of the schematic structure of the power module 107 in the seventh embodiment. In the following description, the same reference numerals are given to the parts common to the power module 101 in the first embodiment and the description thereof is omitted. The power module 107 in the seventh embodiment is a power module for a three-phase motor. As Figure 21 shown, the power module 107 has an outer wall resin 10, three bus bars 20a protruding in the -y direction, three magnetic detection portions 30, and another bus bar 20c protruding in the +y direction. The three bus bars 20a are arranged in the x direction. The three bus bars 20a are the same as the bus bars 20a in the fifth and sixth embodiments, and the three magnetic detection portions 30 are the same as the magnetic detection portions 30 Figure 17 shown. Figure 3 shown.

[0087] The three bus bars 20a respectively correspond to the U phase, V phase, and W phase in the three-phase alternating current.

[0088] The outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 27 and the protective resin 40 and a second portion 17 provided with an insertion hole 11. The first portion 16 and the second portion 17 are integrally formed. Therefore, in Figure 21 FIG., the first portion 16 and the second portion 17 are represented by the same shading. An insertion hole 11 is provided in the second portion 17 for inserting the magnetic detection portion 30. The outer wall resin 10 of the power module 107 has three insertion holes 11 for inserting the three magnetic detection portions 30. When viewed from the insertion direction of the three magnetic detection portions 30, the three insertion holes 11 have shapes corresponding to the outer shape of the three magnetic detection portions 30. The shapes of the three insertion holes 11 are the same as the shapes Figure 4 and Figure 5 shown.

[0089] Figure 22 FIG. is a perspective view showing an example of the schematic structure of the power module 108 in the eighth embodiment. In the following description, the same reference numerals are given to the parts common to the power module 101 in the first embodiment and the description thereof is omitted. The power module 108 in the eighth embodiment is a power module for a three-phase motor. As Figure 22As shown, the power module 108 has an outer wall resin 10, three busbars 20a protruding toward the -y direction side, three magnetic detection portions 30a, and other busbars 20c protruding toward the +y direction side. The three busbars 20a are arranged in a row along the x direction. Each of the three magnetic detection portions 30a is the same as the magnetic detection portion 30a shown in Figure 9 Each of the three busbars 20a is the same as the busbar 20a shown in Figure 17

[0090] The three busbars 20a respectively correspond to the U phase, V phase, and W phase in three-phase alternating current.

[0091] The outer wall resin 10 has a first portion 16 that surrounds at least a part of the current path 27 and the protective resin 40, and a second portion 17 provided with an insertion hole 11. The first portion 16 and the second portion 17 are integrally formed. Therefore, in Figure 22 , the first portion 16 and the second portion 17 are indicated by the same shading. An insertion hole 11 for inserting the three magnetic detection portions 30a is provided in the second portion 17. When viewed from the insertion direction of the three magnetic detection portions 30a, the insertion hole 11 has a shape corresponding to the outer shape of the three magnetic detection portions 30a. The cross-sectional view near each busbar 20a is the same as the cross-sectional view shown in Figure 19

[0092] Figures 23 to 25 FIG. is an explanatory diagram showing a part of the manufacturing process of the power module 101 in the first embodiment. It should be noted that in Figures 23 to 25 , only the structure on the front side (-y direction side) of the power module 101 is depicted, and the protective resin 40 etc. on the back side (+y direction side) are not depicted. In the first step, the busbar 20 shown in Figure 2 is prepared. In the second step, as shown in Figure 23 , an outer wall resin 10 having an insertion hole 11 for inserting the magnetic detection portion 30 is formed by resin molding around the busbar 20. In the third step, as shown in Figure 24 , the magnetic detection portion 30 is inserted into the insertion hole 11 from the +z direction. In the fourth step, as shown in Figure 25 , the magnetic detection portion 30 is fixed by applying an adhesive 12 to the gap of the insertion hole 11.

[0093] Figures 26 to 28 FIG. is an explanatory diagram showing a part of the manufacturing process of the power module 102 in the second embodiment. It should be noted that in Figures 26 to 28 , only the structure on the front side (-y direction side) of the power module 102 is depicted, and the protective resin 40 etc. on the back side (+y direction side) are not depicted. In the first step, the busbar 20 shown in Figure 2 is prepared. As shown in Figure 26 ​​As shown, in the second step, an outer wall resin 10 having an insertion hole 11 for inserting the magnetic detection portion 30a is formed by resin molding around the bus bar 20. As Figure 27 shown, in the third step, the magnetic detection portion 30a is inserted into the insertion hole 11 from the +z direction. As Figure 28 shown, in the fourth step, the magnetic detection portion 30a is fixed by applying an adhesive 12 to the gap of the insertion hole 11.

[0094] Figure 29 and Figure 30 is a perspective view showing an example of a schematic structure of a modified example of the bus bar 20 used in the first to fourth embodiments. Figure 29 The bus bar shown has two main body portions 21, 22 and one current path 23. As Figure 29 shown, the two main body portions 21, 22 are arranged in the y direction. The current path 23 is arranged between the two main body portions 21, 22 and connects the two main body portions 21, 22. The measured current flows in the y direction in the current path 23. Figure 30 The bus bar shown has two main body portions 21, 22, one current path 23 and a notch portion 26. Figure 30 The bus bar in [] is asymmetrical left and right.

[0095] As described above, according to the first to eighth embodiments, the outer wall resin 10 has the insertion hole 11, and when viewed from the insertion direction of the magnetic detection portions 30, 30a, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection portions 30, 30a. Thus, the magnetic detection portions 30, 30a can be inserted into the outer wall resin 10 and easily fixed, and also the position deviation of the magnetic detection portions 30, 30a can be prevented.

[0096] As described above, the present invention has been described using embodiments, but the technical scope of the present invention is not limited to the scope described in the above embodiments. Various changes or improvements can be made to the above embodiments, which are obvious to those skilled in the art. From the description of the claims, it can be seen that the embodiments to which such changes or improvements are applied can also be included in the technical scope of the present invention.

[0097] It should be noted that the execution order of each process such as the actions, sequences, steps, and stages in the devices, systems, programs, and methods shown in the claims, the specification, and the drawings can be implemented in any order as long as it is not specifically stated as "prior to", "before...", etc., and as long as the output of the previous process is not used in the subsequent process. Regarding the action flow in the claims, the specification, and the drawings, even if it is described using "first", "then", etc. for convenience, it does not mean that it must be implemented in that order.

Claims

1. A power module, wherein, The power module has a bus bar, a magnetic detection part, and an outer wall resin. The magnetic detection part has a magnetic detection element, an element part on which the magnetic detection element is fixed, and a substrate on which the element part is fixed. The outer wall resin has an insertion hole for inserting the magnetic detection part. When viewed from the insertion direction of the magnetic detection part, the insertion hole has a shape corresponding to the outer shape of the magnetic detection part. A part of the wall surface of the outer wall resin forming the insertion hole has a positioning part that contacts the element part of the magnetic detection part.

2. The power module according to claim 1, wherein, The magnetic detection part has a magnetic detection element and a substrate on which the magnetic detection element is fixed. The surface of the substrate having the magnetic detection element is orthogonal to the insertion direction.

3. The power module according to claim 1, wherein, The magnetic detection part has a magnetic detection element and a substrate on which the magnetic detection element is fixed. The surface of the substrate having the magnetic detection element is parallel to the insertion direction.

4. The power module according to claim 1, wherein, The outer wall resin covers a part of the bus bar.

5. The power module according to claim 1, wherein In the power module, three of the bus bars are arranged in a direction orthogonal to the extending direction of the bus bar.

6. The power module according to claim 1, wherein, The power module has only one bus bar.

7. The power module according to claim 1, wherein The magnetic detection part is inserted into the insertion hole, and there is a gap between the wall surface of the outer wall resin forming the insertion hole and the side surface of the magnetic detection part.

8. The power module according to claim 1, wherein, The magnetic detection part is fixed in the insertion hole in a state where there is a gap between the wall surface of the outer wall resin forming the insertion hole and the side surface of the magnetic detection part.

9. The power module according to claim 1, wherein, The magnetic detection part is inserted into the insertion hole, and the lower surface of the wall surface of the outer wall resin forming the insertion hole contacts the lower end part of the magnetic detection part.

10. The power module according to claim 1, wherein, The magnetic detection part has a magnetic detection element and a substrate on which the magnetic detection element is fixed. The magnetic detection part is inserted into the insertion hole, and a part of the wall surface of the outer wall resin forming the insertion hole contacts the lower surface of the substrate.

11. The power module according to claim 1, wherein, The outer wall resin has a first part surrounding at least a part of the bus bar and a second part provided with the insertion hole.

12. The power module according to claim 1, wherein, The bus bar is not exposed in the insertion hole.

13. The power module according to claim 1, wherein, The surface of the insertion hole orthogonal to the insertion direction has a shape complementary to the outer shape of the magnetic detection part.

14. An outer wall resin for a power module, which is an outer wall resin for a power module having a bus bar and a magnetic detection unit, wherein, The magnetic detection part includes a magnetic detection element, an element part on which the magnetic detection element is fixed, and a substrate on which the element part is fixed. The outer wall resin for the power module has an insertion hole for inserting the magnetic detection part, and a part of the wall surface of the outer wall resin for the power module forming the insertion hole has a positioning part that contacts the element part of the magnetic detection part. When viewed from the insertion direction of the magnetic detection part, the insertion hole has a shape corresponding to the outer shape of the magnetic detection part.

15. A manufacturing method of a power module, which is a manufacturing method of a power module having a bus bar and a magnetic detection unit, wherein, The magnetic detection part includes a magnetic detection element, an element part on which the magnetic detection element is fixed, and a substrate on which the element part is fixed. The manufacturing method of the power module has the following steps: A step of resin-molding the bus bar to form an outer-wall resin, the outer-wall resin having an insertion hole for inserting the magnetic detection unit, and a part of a wall surface of the outer-wall resin forming the insertion hole having a positioning portion for contacting the element portion of the magnetic detection unit; And A step of inserting the magnetic detection unit into the insertion hole so that the element portion of the magnetic detection unit contacts the positioning portion, When viewed from the insertion direction of inserting the magnetic detection unit into the outer-wall resin, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit.

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