Transformer and rectifier element mounting structure

Abstract

The invention provides a transformer and a mounting structure of a rectifying element, which are suitable for improving the conversion efficiency of the rectifying element. A transformer and rectifier element mounting structure is provided with: a transformer (120); and a rectifying element unit (112) comprising a plurality of rectifying elements connected to the transformer (120), and an electrical path connecting the transformer (120) and the rectifying element unit (112) is formed as a straight line having substantially the same length with respect to each of the plurality of rectifying elements constituting the rectifying element unit (112).

Description

Technical Field

[0001] The present invention relates to the mounting structure of transformers and rectifier elements used, for example, in DC-DC converters of DC power supply devices. Background Technology

[0002] Traditionally, DC power supply devices consist of a combination of AC-DC converters and / or DC-DC converters, which obtain the desired DC voltage by further stepping up or down the DC input, or the DC after AC has been converted to DC.

[0003] Such a DC-DC converter typically includes: a transformer for changing voltage, a rectifier such as a MOSFET connected to the secondary winding side of the transformer, a mounting plate for mounting the rectifier, and a busbar for electrically connecting the rectifier to the transformer (see, for example, Patent Documents 1 and 2). Existing technical documents Patent documents

[0004] Patent Document 1: Japanese Patent Application Publication No. 2011-50160 Patent Document 2: Japanese Patent Application Publication No. 2014-121117 Summary of the Invention The problem that the invention aims to solve

[0005] In DC-DC converters based on the aforementioned prior art, there is a problem that, in recent years, there has been a demand for further improvements in conversion efficiency due to the requirement for high current in DC power supply devices.

[0006] Therefore, the main objective of this invention is to provide a suitable installation structure for a transformer and a rectifier element that improves the conversion efficiency of the rectifier element. Technical means for solving problems

[0007] The first embodiment of the present invention is an installation structure for a transformer and rectifier elements, comprising a transformer and a plurality of rectifier elements connected to the transformer, wherein the electrical path connecting the transformer and the plurality of rectifier elements is formed as a straight line of approximately the same length with respect to each of the plurality of rectifier elements.

[0008] The second aspect of the present invention is based on the installation structure of the transformer and rectifier elements of the first aspect of the present invention, wherein the plurality of rectifier elements are mounted on a mounting base plate, and the electrical path is formed such that, in a top view of the mounting base plate, it intersects with the line, i.e., the wiring, along the arrangement of the plurality of rectifier elements, and the transformer is arranged opposite to the surface containing the wiring.

[0009] The third aspect of the present invention is that, based on the installation structure of the transformer and rectifier element in the second aspect of the present invention, the wiring is formed as a line segment, the electrical path is formed in a generally orthogonal orientation relative to the wiring, and the surface including the wiring is formed as a plane.

[0010] The fourth aspect of the present invention is that, based on the installation structure of the transformer and rectifier element in the second aspect of the present invention, the transformer is adjacent to the mounting substrate across the electrical path.

[0011] The fifth aspect of the present invention is based on the installation structure of the transformer and rectifier elements in the third aspect of the present invention, and includes a first heat sink, which is electrically connected to the plurality of rectifier elements via the mounting substrate, and extends out in a direction substantially parallel to the wiring harness to form a conductive path.

[0012] The sixth aspect of the present invention is that, based on the installation structure of the transformer and rectifier elements in the third aspect of the present invention, a second heat sink is provided, which is connected to the output side of the transformer, whose polarity is different from the electrical path connecting the transformer and the plurality of rectifier elements, and extends out in a direction generally parallel to the busbar to form a conductive path.

[0013] The seventh aspect of the present invention is that, based on the installation structure of the transformer and rectifier element in the sixth aspect of the present invention, the transformer is installed on the second heat sink.

[0014] The eighth aspect of the present invention is based on the installation structure of the transformer and rectifier elements in the fifth aspect of the present invention, wherein the mounting substrate has: a first sub-mounting substrate fixed to one main surface of the first heat sink; and a second sub-mounting substrate fixed to the other main surface of the first heat sink, wherein the plurality of rectifier elements are mounted on each of the first sub-mounting substrate and the second sub-mounting substrate.

[0015] The ninth aspect of the present invention is based on the installation structure of the transformer and rectifier elements in the fifth or sixth aspect of the present invention, wherein the electrical path is formed as a busbar that electrically connects the transformer and the plurality of rectifier elements, and the dimension of the second side of the busbar along the side of the busbar is greater than or less than the dimension of the first side of the transformer.

[0016] The tenth aspect of the present invention is that, based on the installation structure of the transformer and rectifier element in the fifth aspect of the present invention, a cooling path is provided inside the first heat sink for the passage of refrigerant.

[0017] The eleventh aspect of the present invention is that, based on the installation structure of the transformer and rectifier element in the sixth aspect of the present invention, a cooling path is provided inside the second heat sink for the passage of refrigerant.

[0018] The twelfth embodiment of the present invention is an arrangement of a transformer and rectifier component mounting structure, which has multiple transformer and rectifier component mounting structures of the third embodiment of the present invention as sub-structures, and the sub-structures are arranged along the wiring.

[0019] The thirteenth aspect of the present invention is an arrangement of a transformer and rectifier mounting structure, having at least one pair of transformer and rectifier mounting structures of the second aspect of the present invention as sub-structures, wherein in the pair of said sub-structures, the mounting substrates are respectively arranged opposite to each other.

[0020] The fourteenth embodiment of the present invention is a DC power supply unit having the arrangement of the transformer and rectifier components of the twelfth or thirteenth embodiment of the present invention, and the output from the installation structure of the transformer and rectifier components is used as DC output.

[0021] The fifteenth aspect of the present invention is a DC power supply device having multiple DC power supply units according to the fourteenth aspect of the present invention, and outputting the sum of the outputs of each of the DC power supply units. Invention Effects

[0022] According to the present invention, a transformer and a mounting structure for rectifier elements that are suitable for improving the conversion efficiency of rectifier elements can be provided.

[0023] The above-mentioned objects, other objects, features and advantages of the present invention can be further understood from the following specific embodiments with reference to the accompanying drawings. Attached Figure Description

[0024] Figure 1 This is a perspective view showing a DC-DC converter having an installation structure of the transformer and rectifier elements according to an embodiment of the present invention. Figure 2 This is a front view showing a DC-DC converter having an installation configuration of the transformer and rectifier elements according to an embodiment of the present invention. Figure 3 This is a rear view showing a DC-DC converter having an installation configuration of the transformer and rectifier elements according to an embodiment of the present invention. Figure 4 This is a left view showing a DC-DC converter having an installation configuration of the transformer and rectifier elements according to an embodiment of the present invention. Figure 5 This is an exploded perspective view showing a DC-DC converter having an installation structure of the transformer and rectifier elements according to an embodiment of the present invention. Figure 6This is a block diagram schematically illustrating the configuration of a DC power supply device, including a DC-DC converter with a mounting structure having the transformer and rectifier elements involved in the embodiments of the present invention. Figure 7 This is a front view showing the installation structure of the transformer and rectifier components according to an embodiment of the present invention. Figure 8 This is a right view showing the installation structure of the transformer and rectifier components according to an embodiment of the present invention. Figure 9 Based on Figure 7 A sectional view of the main part of the IX-IX line. Figure 10 This is an exploded perspective view showing the installation structure of the transformer and rectifier components according to an embodiment of the present invention. Figure 11 This is an exploded perspective view showing the installation structure of the transformer and rectifier components according to an embodiment of the present invention. Figure 12 This is a schematic diagram illustrating the configuration of the transformer and rectifier elements in the installation structure of the transformer and rectifier elements according to an embodiment of the present invention. Figure 13 This is a schematic diagram illustrating the configuration of the transformer and rectifier elements in an installation structure according to another embodiment of the present invention. Figure 14 This is a schematic diagram illustrating the configuration of the transformer and rectifier elements in an installation structure according to another embodiment of the present invention. Detailed Implementation

[0025] The following describes the installation structure of the transformer and rectifier element of the present invention through this embodiment.

[0026] (DC-DC converter) A DC-DC converter (hereinafter referred to as a DC-DC converter) will be described as an example of a DC power supply unit having the installation structure of the transformer and rectifier elements according to embodiments of the present invention. The DC-DC converter is configured, for example, as the final stage of a DC power supply device that converts an externally input AC power supply into a DC current of a specified voltage.

[0027] Figure 1 This is a perspective view showing the DC-DC converter 1 according to an embodiment of the present invention. Figure 2 This is a front view showing the DC-DC converter 1 according to an embodiment of the present invention. Figure 3 This is a rear view showing the DC-DC converter 1 according to an embodiment of the present invention. Figure 4This is a left view showing the DC-DC converter 1 according to an embodiment of the present invention. Figure 5 This is an exploded perspective view showing the main parts of the DC-DC converter 1 according to an embodiment of the present invention. Figure 6 This is a block diagram schematically showing the configuration of a DC power supply device, including the DC-DC converter 1 according to an embodiment of the present invention.

[0028] As shown in the figures, the DC-DC converter 1 according to the embodiments of the present invention comprises, as the main components: a negative side block 10, which is connected to the positive and negative sides of the secondary side output of a center-tapped transformer, is subjected to voltages on both the positive and negative sides, and outputs the current output from the secondary side after rectification; and a positive side block 20, which is connected to the center tap of the transformer and is subjected to the voltage of the center tap.

[0029] The negative side block 10 has a transformer rectifier block 11 consisting of four transformer rectifier blocks, and a first heat sink 12 with a generally rectangular planar shape and a first terminal busbar 14 that mounts and electrically connects to the transformer rectifier blocks 11. The first heat sink 12 and the first terminal busbar 14 form a conductive path on the negative side of the DC-DC converter 1.

[0030] The transformer rectifier block 11 is configured as four identical sub-transformer rectifier blocks connected in parallel, namely the first sub-transformer rectifier block 11A, the second sub-transformer rectifier block 11B, the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D.

[0031] The following explanation is based on the orthogonal coordinates shown in the figures. The arrangement direction of the first sub-transformer rectifier block 11A, the second sub-transformer rectifier block 11B, the third sub-transformer rectifier block 11C, and the fourth sub-transformer rectifier block 11D is set as the horizontal direction (left-right direction). The arrangement direction of the first sub-transformer rectifier block 11A, the third sub-transformer rectifier block 11C, the second sub-transformer rectifier block 11B, and the fourth sub-transformer rectifier block 11D is set as the vertical direction (up-down direction). The direction orthogonal to both the horizontal and vertical directions is set as the thickness direction (front-back direction).

[0032] Therefore, specifically, when viewing the DC-DC converter 1 from the front, the first sub-transformer rectifier block 11A is positioned on the upper left, the second sub-transformer rectifier block 11B is adjacent to the first sub-transformer rectifier block 11A on the right and positioned on the upper right, the third sub-transformer rectifier block 11C is adjacent to the first sub-transformer rectifier block 11A on the lower left, and the fourth sub-transformer rectifier block 11D is adjacent to the third sub-transformer rectifier block 11C on the right and to the lower side of the second sub-transformer rectifier block 11B and positioned on the lower right.

[0033] Furthermore, as with the letters “A” to “D” at the end of the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D mentioned above, in the accompanying drawings referred to in the description of this embodiment, with a few exceptions, multiple constituent elements having the same or corresponding configuration are distinguished by the uppercase or lowercase letters assigned to the end of the numerical designation in terms of their configuration or position.

[0034] constitute Figures 1-5 The first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D shown in the transformer rectifier block 11 each have... Figure 6 The DC power supply device shown is configured as a synchronous full-wave rectifier circuit comprising a transformer 311, which is a center-tapped transformer, and a rectifier element 312, such as a MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor). The rectifier element 312 is configured as a unit consisting of a positive-side rectifier element 312A connected to the positive terminal of the secondary side of the transformer 311 and a negative-side rectifier element 312B connected to the negative terminal of the secondary side of the transformer 311, connected in parallel. A detailed description of the transformer-rectifier block 11 will follow later.

[0035] In addition, Figures 1-5 In the transformer rectifier block 11 shown, the positive side rectifier element 312A and the negative side rectifier element 312B are each configured as a group of multiple MOSFETs, but they can also be configured as a single MOSFET.

[0036] The first heat sink 12 is a plate-shaped component made of copper, aluminum or other conductive metals with a specified thickness, configured to form a conductive path extending to the right along the arrangement direction of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and thus has a generally rectangular shape.

[0037] The first heat sink 12 is equipped with a cooling path, namely a refrigerant piping 13, which circulates refrigerant along the direction of the arrow in the figure. The refrigerant piping 13 cools the first heat sink 12 by circulating refrigerant such as water using a circulation device in a DC power supply device (not shown).

[0038] Like the first heat sink 12, the first terminal busbar 14 is a plate-shaped component of a specified thickness made of copper, aluminum, or other conductive metal, configured to form a conductive path extending further to the right along the extension direction of the first heat sink 12, and thus has a generally rectangular shape. The first terminal busbar 14 is electrically and thermally connected to the first heat sink 12 via the connecting member 15, and a DC output is taken out from the end 14E.

[0039] The positive side block 20 has connection terminals 21A, 21B, 21C, and 21D for electrical connection to the center tap of the transformer 120 of the transformer rectifier block 11, and a conductive second heat sink 22 and a second terminal busbar 24 for electrical connection to the transformer rectifier block 11. The second heat sink 22 and the second terminal busbar 24 form a conductive path on the positive side of the DC-DC converter 1.

[0040] Connection terminal 21A is connected to the first sub-transformer rectifier block 11A. Connection terminal 21B is connected to the second sub-transformer rectifier block 11B. Connection terminal 21C is connected to the third sub-transformer rectifier block 11C. Connection terminal 21D is connected to the fourth sub-transformer rectifier block 11D.

[0041] Connection terminals 21A to 21D protrude from the surface of the second heat sink 22, forming a gap C between the transformer rectifier block 11 and the second heat sink 22 in the DC-DC converter 1. Connection terminals 21A to 21D are preferably made of copper, but any material can be used as long as it is a conductive metal.

[0042] Inside the second heat sink 22, there is a pair of cooling paths, namely refrigerant piping 23, for the refrigerant to circulate along the direction of the arrow in the figure. The refrigerant piping 23 cools the second heat sink 22 by circulating refrigerant such as water using a circulation device in a DC power supply device (not shown).

[0043] The second heat sink 22 is configured as a combination of a pair of heat sinks, namely the first sub-heat sink 22a and the second sub-heat sink 22b, which are arranged vertically adjacent to each other and have a rectangular planar shape. The first sub-heat sink 22a and the second sub-heat sink 22b are each plate-shaped components made of copper, aluminum or other conductive metals with a specified thickness. They are parallel to the first heat sink 12 and are configured to form a conductive path extending to the right along the arrangement direction of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, thus forming components with a generally rectangular shape.

[0044] A first sub-refrigerant pipe 23a, which serves as one side of the refrigerant pipe 23, is disposed inside the first sub-heat sink 22a, and a second sub-refrigerant pipe 23b, which serves as the other side of the refrigerant pipe 23, is disposed inside the second sub-heat sink 22b.

[0045] Like the second heat sink 22, the second terminal busbar 24 is a plate-shaped component of a specified thickness made of copper, aluminum, or other conductive metal, configured to form a conductive path extending further to the right along the extension direction of the second heat sink 22, and thus has a generally rectangular shape. The second terminal busbar 24 is electrically and thermally connected to the second heat sink 22 via the connecting member 25, and a DC output is taken out from the end 24E.

[0046] (DC power supply device) Reference Figure 6 The block diagram illustrates the main components of a DC power supply device, including the DC-DC converter 1 according to an embodiment of the present invention.

[0047] The DC power supply device includes: an AC-DC converter 100 that accepts an input AC current Ia and converts it into an output Oa as a square wave; a primary DC-DC converter 200 that transforms the output Oa of the AC-DC converter 100 into an output Od1; and a secondary DC-DC converter 300 that transforms and rectifies the output Od1 of the primary DC-DC converter 200 into an output Od2, which is the final DC current of the DC power supply device. In the secondary DC-DC converter 300, the output Od2 uses the positive terminal OdP and the negative terminal OdN as its output terminals. However, the DC power supply device, including the DC-DC converter 1 according to the embodiments of the present invention, is not limited to the above configuration. It can be any device that is composed of a combination of an AC-DC converter and / or a DC-DC converter, and obtains the desired voltage by further stepping up or down the DC input, or the DC after AC-DC conversion.

[0048] The AC-DC converter 100 is configured as a PFC circuit. The primary DC-DC converter 200 and the secondary DC-DC converter 300 are configured as a switching regulator. The secondary DC-DC converter 300 is an example of the DC power supply unit of the present invention, equivalent to... Figures 1-5 The DC-DC converter 1 shown is shown.

[0049] The secondary DC-DC converter unit 300 consists of four identical sub-transformer rectifier blocks connected in parallel: a first sub-transformer rectifier block 310A, a second sub-transformer rectifier block 310B, a third sub-transformer rectifier block 310C, and a fourth sub-transformer rectifier block 310D. The first sub-transformer rectifier block 310A is equivalent to the first sub-transformer rectifier block 11A in the DC-DC converter 1, the second sub-transformer rectifier block 310B is equivalent to the second sub-transformer rectifier block 11B in the DC-DC converter 1, the third sub-transformer rectifier block 310C is equivalent to the third sub-transformer rectifier block 11C in the DC-DC converter 1, and the fourth sub-transformer rectifier block 310D is equivalent to the fourth sub-transformer rectifier block 11D in the DC-DC converter 1.

[0050] The following description uses the first sub-transformer rectifier block 310A as an example to explain the structure of the sub-transformer rectifier block. The first sub-transformer rectifier block 310A is configured as a transformer 311, which is a center-tapped transformer, a positive-side rectifier element 312A and a negative-side rectifier element 312B connected to the transformer 311, and a synchronous full-wave rectifier circuit with a mounting plate 313 on which the positive-side rectifier element 312A and the negative-side rectifier element 312B are mounted.

[0051] As terminals, transformer 311 has: a primary side terminal 311a1 on the positive side, which receives the positive side of the output Od1 of the primary DC-DC converter 200; a primary side terminal 311b1 on the negative side, which is connected to the primary side terminal on the positive side of the transformer of the adjacent second sub-transformer rectifier block 310B; a secondary side terminal 311a2 and a secondary side terminal 311b2 of the same polarity, which are subjected to the transformed voltage; and a center tap 311c, which imparts a reference potential to the secondary side terminal 311a2 and the secondary side terminal 311b2.

[0052] Furthermore, the primary terminals of the transformers of each of the first sub-transformer rectifier blocks 310A to the fourth sub-transformer rectifier block 310D are connected in series. Therefore, the negative terminal of the output Od1 of the primary DC-DC converter unit 200 is connected to the primary terminal of the negative terminal of the transformer of the fourth sub-transformer rectifier block 310D, and the primary terminals of the transformers of the other sub-transformer rectifier blocks are connected to each other at opposite poles.

[0053] As described above, the rectifier element 312 is configured as a unit consisting of a positive-side rectifier element 312A connected to the positive terminal of the secondary side of the transformer 311 and a negative-side rectifier element 312B connected to the negative terminal of the secondary side of the transformer 311, connected in parallel. Specifically, the drain electrode of the positive-side rectifier element 312A is connected to the secondary side terminal 311a2, and the drain electrode of the negative-side rectifier element 312B is connected to the secondary side terminal 311b2. Furthermore, the source electrodes of both the positive-side rectifier element 312A and the negative-side rectifier element 312B are connected to the negative terminal OdN of the secondary DC-DC converter unit 300.

[0054] Furthermore, as mentioned above, the positive-side rectifier element 312A and the negative-side rectifier element 312B are each specifically configured as a group of one or more MOSFETs.

[0055] In the secondary DC-DC converter 300, several electrical paths connecting the various parts are configured as printed wiring, circuit wiring, or electrical paths of components independent of the embedded mounting substrate 313.

[0056] Specifically, the electrical path between the secondary side 311a2 of the positive terminal of the transformer 311 and the mounting substrate 313 is configured as an electrical path 314a based on a component independent of the wiring embedded in the mounting substrate 313. The electrical path between the secondary side 311b2 of the negative terminal of the transformer 311 and the mounting substrate 313 is configured as an electrical path 314b based on a component independent of the wiring embedded in the mounting substrate 313.

[0057] The electrical path from electrical path 314a to the drain electrode of the positive-side rectifier 312A of the rectifier 312 is configured as electrical path 318a based on the wiring of the embedded mounting substrate 313. The electrical path from electrical path 314b to the drain electrode of the negative-side rectifier 312B of the rectifier 312 is configured as electrical path 318b based on the wiring of the embedded mounting substrate 313.

[0058] The electrical path from the source electrode of the positive-side rectifier 312A of the rectifier 312 to the connection point (hereinafter, "connection point") CG of the respective source electrodes of the positive-side rectifier 312A and the negative-side rectifier 312B is configured as an electrical path 315a based on a component independent of the wiring of the embedded mounting substrate 313. The electrical path from the source electrode of the negative-side rectifier 312B of the rectifier 312 to the connection point CG is configured as an electrical path 315b based on a component independent of the wiring of the embedded mounting substrate 313.

[0059] The electrical path between connection point CG and the negative terminal OdN of the output Od2 of the secondary DC-DC converter 300 is configured as an electrical path 316 based on a component independent of the wiring of the embedded mounting substrate 313. The electrical path between the center tap 311c of the transformer 311 and the positive terminal OdP of the output Od2 of the secondary DC-DC converter 300 is configured as an electrical path 317 based on a component independent of the wiring of the embedded mounting substrate 313.

[0060] In the first sub-transformer rectifier block 310A with the above configuration, by alternately applying control voltages from the drive circuit 319 of the secondary DC-DC converter 300 to the gate electrodes of the positive-side rectifier element 312A and the negative-side rectifier element 312B, the positive-side rectifier element 312A and the negative-side rectifier element 312B are switched, and the output of the secondary side of the transformer 311 is rectified. Furthermore, the rectified pulse current can also be... Figure 6 A smoothing circuit (not shown) is used to smooth it. This yields the final DC current in the DC power supply unit.

[0061] In parallel with the operation of the first sub-transformer rectifier block 310A, the second sub-transformer rectifier block 310B, the third sub-transformer rectifier block 310C, and the fourth sub-transformer rectifier block 310D also perform the same operation. Then, the DC output of the DC power supply device is obtained by summing the DC current of the final stage of each sub-transformer rectifier block.

[0062] (Transformer rectifier block) The transformer-rectifier block 11 incorporated into the installation structure of the transformer and rectifier elements according to the embodiments of the present invention will be described. The transformer-rectifier block 11 is a block in the DC-DC converter 1 that transforms and rectifies the primary output voltage from AC to DC, outputting DC current as a DC current to the negative side block 10 and the positive side block 20 of the DC-DC converter 1. Furthermore, as described above, the first sub-transformer-rectifier block 11A to the fourth sub-transformer-rectifier block 11D respectively correspond to… Figure 6 The first sub-transformer rectifier block 310A to the fourth sub-transformer rectifier block 310D are shown.

[0063] Figure 7 This is a front view showing the transformer rectifier block 11. Figure 8 This is a right view showing the transformer rectifier block 11. Figure 9 Based on Figure 7 A sectional view of the main part of the IX-IX line. Figure 10 This is a perspective view showing the transformer rectifier block 11. However, in Figure 10 A portion of it will be shown as an exploded diagram.

[0064] As a main component, the transformer rectifier block 11 includes: a circuit section 110, which includes at least a rectifier element section 112; a transformer 120 for transformation, which is electrically connected to the rectifier element section 112; and a conductive section 130, which forms an electrical path between the transformer 120, the circuit section 110 and the negative terminal block 10.

[0065] The circuit section 110 includes: a mounting substrate 111, comprising a first sub-mounting substrate 111A exposed to the surface side in the DC-DC converter 1 and a second sub-mounting substrate 111B facing the second heat sink 22 of the positive electrode side block 20; and a rectifier element section 112 and a drive circuit 113, mounted on the respective sub-mounting substrates of the first sub-mounting substrate 111A and the second sub-mounting substrate 111B. The mounting substrate 111 corresponds to... Figure 6 The mounting base plate 313 of each of the first sub-transformer rectifier blocks 310A to the fourth sub-transformer rectifier block 310D shown.

[0066] Hereinafter, the configuration of the circuit section 110 will be described using the first sub-mount substrate 111A side as an example, but the second sub-mount substrate 111B side also has a basically the same configuration.

[0067] The first sub-mounting substrate 111A is formed as a rectangular plate with a surface 111F and a back surface 111R as a pair of main surfaces, and a rectifier element 112 and a drive circuit 113 are mounted on the surface 111F.

[0068] The rectifier element section 112 is configured as a pair of rectifier element groups, rectifier element group 112A and rectifier element group 112B, arranged in a horizontal row with predetermined intervals on the surface 111F of the first sub-mounting substrate 111A. Each of the rectifier element groups 112A and rectifier element group 112B is further composed of a plurality of rectifier elements arranged in a horizontal row at equal intervals and electrically connected in parallel, in a layout form as line segments, when viewed from above along the first sub-mounting substrate 111A. That is, all the rectifier elements constituting the rectifier element section 112 are arranged in a straight line in the horizontal direction when viewed from above along the first sub-mounting substrate 111A.

[0069] Furthermore, the wiring AL formed by the individual rectifiers of the plurality of rectifiers in the rectifier element section 112 serves as the reference for the orthogonal coordinates in each figure, defining the orientation of each part of the DC-DC converter 1, including the installation structure of the transformer and rectifiers of the present invention and the transformer rectifier block 11.

[0070] For example, regarding the configuration of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11D constituting the transformer rectifier block 11, the arrangement direction of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and the arrangement direction of the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D are approximately parallel to the busbar line AL. The arrangement direction of the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C, and the arrangement direction of the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D are approximately orthogonal to the busbar line AL.

[0071] Similarly, the first heat sink 12 and the first terminal busbar 14 of the negative electrode side block 10, and the second heat sink 22 and the second terminal busbar 24 of the positive electrode side block 20 are formed in a manner that extends in a direction that is generally parallel to the busbar AL.

[0072] Rectifier element group 112A is equivalent to Figure 6 The positive-side rectifier element 312A in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown is equivalent to the rectifier element group 112B. Figure 6 The negative side rectifier element 312B in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown.

[0073] Each of the plurality of rectifier elements constituting the rectifier element section 112 is a component that rectifies the output from the transformer 120, as described above; for example, a MOSFET is used. However, the specific configuration of each rectifier element constituting the rectifier element section 112 is not limited as long as it is an active component capable of rectification; for example, an IGBT (Insulated Gate Bipolar Transistor) can be used. Furthermore, each rectifier element constituting the rectifier element section 112 is preferably a power transistor capable of handling a high current of at least 50A.

[0074] Specifically, refer to Figure 7 and Figure 9 Taking the rectifier 121B1 at the right end of the rectifier element group 112B as an example, each rectifier element constituting the rectifier element section 112 has: a drain electrode 112a, which is provided to be exposed to the surface facing the mounting substrate 111F; a source electrode 112b, which extends downward along the surface 111F of the mounting substrate 111; and a gate electrode 112c, which extends upward along the surface 111F of the mounting substrate 111.

[0075] The drive circuit 113 is a circuit connected to the gate electrode of each of the rectifier elements constituting the rectifier element section 112, and is a means of performing the switching operation of the rectifier element section 112. Furthermore, in the figures, the drive circuit 113 is shown as a schematic single block, namely, each of the first sub-drive circuit 113a that drives the rectifier element group 112A and the second sub-drive circuit 113b that drives the rectifier element group 112B.

[0076] Transformer 120 is a center-tapped planar transformer, comprising a PQ core 123 in which multiple primary-side coils 121 (thin flat wire coils) and multiple secondary-side coils 122 (flexible substrate coils) are alternately layered and wound. Transformer 120 is equivalent to Figure 6 The transformer 311 in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown.

[0077] Multiple primary-side coils 121 are connected via a primary-side start end 121a, which serves as the starting point of winding, and a primary-side end end 121b, which serves as the ending point of winding. Figures 1-5 The upstream section of the DC-DC converter 1, i.e., the primary-side output circuit (not shown), is electrically connected. Specifically, the primary-side start end 121a and primary-side terminal 121b are led out to the upper side of the transformer 120 and connected to the primary-side output circuit of the DC-DC converter 1 via wires (not shown).

[0078] Furthermore, the primary-side output circuit of the aforementioned DC-DC converter 1 is in Figure 6 The middle section is shown as the primary DC-DC converter unit 200. Figure 7The primary-side start end 121a and primary-side end 121b of the primary-side coil 121 shown are in Figure 6 The primary side terminal 311a1 on the positive electrode side and the primary side terminal 311b1 on the negative electrode side are shown in the middle.

[0079] Multiple secondary-side coils 122 are a stack of flexible substrate coils having a secondary-side start end 122a as the starting point of winding and a secondary-side intermediate end 122c as the ending point of winding, and flexible substrate coils having a secondary-side start end 122b as the starting point of winding and a secondary-side intermediate end 122c as the ending point of winding. The secondary-side start ends 122a and 122b are assigned potentials of different polarities. That is, if the secondary-side start end 122a is positive, then the secondary-side start end 122b is negative, and vice versa. The secondary-side intermediate end 122c is assigned a neutral point to the secondary-side start ends 122a and 122b. Specifically, the secondary-side start ends 122a and 122b are assigned a negative potential to the DC-DC converter 1. The secondary side intermediate terminal 122c is given a positive potential to DC-DC converter 1.

[0080] The secondary side starting ends 122a and 122b are electrically connected to the mounting substrate 111 of the circuit section 110. The secondary side intermediate end 122c is electrically connected to the positive electrode block 20.

[0081] Specifically, in Figure 7 In the middle, the secondary side starting terminals 122a and 122b, and the secondary side intermediate terminal 122c are led out to the lower side of the transformer 120, such as... Figure 7 As shown, they are arranged in a horizontal column.

[0082] The secondary-side starting ends 122 of the multiple secondary-side coils 122 are coupled to cylindrical coupling terminals 124a. The coupling terminals 124a are fixed to the first sub-mounting substrate 111A via a busbar 131a of the first sub-conductive portion 130a (described later), thereby being electrically connected to the rectifier element portion 112.

[0083] The secondary-side starting ends 122b of the multiple secondary-side coils 122 are coupled to cylindrical coupling terminals 124b. The coupling terminals 124b are fixed to the first sub-mounting substrate 111A via a busbar 131b of the second sub-conductive portion 130b (described later), thereby being electrically connected to the rectifier element portion 112.

[0084] The secondary side intermediate terminals 122c of multiple secondary side coils 122 are connected to cylindrical coupling terminals 124c. The coupling terminals 124c of the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D are fixed to the positive side block 20 and electrically connected thereto via the respective connection terminals 21A to 21D.

[0085] also, Figure 7 The secondary side start end 122a of the secondary side coil 122 shown is at Figure 6 The middle part corresponds to the secondary side terminal 311a2 on the positive electrode side. Figure 7 The secondary side start end 122b of the secondary side coil 122 shown is in Figure 6 The middle part corresponds to the secondary side terminal 311b2 on the positive electrode side. Figure 7 The secondary side intermediate terminal 122c of the secondary side coil 122 shown is in Figure 6 The middle part is equivalent to the center tap 311c.

[0086] The conductive part 130 is composed of a first sub-conductive part 130a, which forms an electrical path of negative potential between the transformer 120 and the negative side block 10 via the connecting terminal 124a, and a second sub-conductive part 130b, which forms an electrical path of negative potential between the transformer 120 and the negative side block 10 via the connecting terminal 124b.

[0087] The first sub-conductive section 130a consists of busbar 131a and busbar 132a (see reference) that electrically connect the coupling terminal 124a and the rectifier element section 112 and connect the transformer 120 and the mounting base plate 111. Figure 7 It consists of the area enclosed by double-dotted lines and the connecting pin 133a.

[0088] The second sub-conductive section 130b consists of busbar 131b and busbar 132b (see reference) that electrically connect the coupling terminal 124b and the rectifier element section 112 and connect the transformer 120 and the mounting base plate 111. Figure 7 It consists of the area enclosed by double-dotted lines and the connecting pin 133b.

[0089] The first sub-conductive portion 130a and the second sub-conductive portion 130b, viewed from above along the mounting substrate 111, have a left-right symmetrical shape relative to a straight line passing through the coupling terminal 124b in the vertical direction. Specifically, busbars 131a and 131b have a left-right symmetrical shape, and busbars 132a and 132b have the same shape. Therefore, in the following description, reference will be made to... Figures 7 to 10 The second sub-conductive part 130b will be used as an example for explanation, but the first sub-conductive part 130a has the same configuration except for the shape described above.

[0090] Busbar 131b is a plate-shaped component made of copper, aluminum, or other conductive metals, in single or multiple layers, with a specified thickness. When the dimension of the wiring AL along the rectifier element group 112B is defined as the width dimension, the width (second side) of busbar 131b on the rectifier element group 112B side is greater than the width (first side) on the transformer 120 connection terminal 124b side, and the width gradually increases therebetween, giving it a generally trapezoidal shape when viewed from above along the mounting substrate 111.

[0091] Thus, when viewed from the front along the mounting substrate 111, the busbar 131b extends in a direction that is substantially orthogonal to the wiring AL of the rectifier element group 112B. The electrical path formed by the busbar 131b, connecting the connection terminal 124b and each of the multiple rectifier elements constituting the rectifier element group 112B, is formed as a straight line of substantially the same length with respect to each of the multiple rectifier elements.

[0092] In this configuration, the transformer 120 is positioned to sandwich the busbar 131b in the middle and to be opposite the wiring AL of the rectifier element group 112B.

[0093] exist Figure 8 , Figure 9 As shown in the right-hand view, the busbar 131b is arranged in a configuration where the contact surface C1, which contacts the end face of the coupling terminal 124b, and the contact surface C2, which contacts the mounting substrate 111, are parallel and offset in the front-rear direction. It has a shape that is bent by corrugated folds that include one convex fold and one concave fold.

[0094] Busbar 132b is a plate-shaped component made of copper, aluminum, or other conductive metal, with a generally rectangular shape when viewed from above. Specifically, such as... Figure 9 As shown, the busbar 132b extends in the vertical direction from a position overlapping with the busbar 131b to a position opposite to the plurality of rectifier elements constituting the rectifier element section 112. The busbar 132b is preferably formed of a single-layer metal plate with a thickness greater than that of the metal plate used for the busbar 131b.

[0095] Busbar 132b is fixed to the side of mounting substrate 111 where the rectifier element 112 and drive circuit 113 are not mounted, i.e., the back side 111R. At this time, mounting substrate 111 is sandwiched between the contact surfaces C2 of busbar 132b and busbar 131b that are in contact with mounting substrate 111.

[0096] Next, as Figure 9 and Figure 10 As shown, the busbar 132b of the transformer rectifier block 11 is relative to the negative side block 10 (refer to...). Figure 11The first heat sink 12 is mechanically fixed and insulated from the first heat sink 12 via an insulating member 117. Specifically, the surface in the first heat sink 12 where the busbar 132b is fixed is recessed by an amount corresponding to the thickness of the busbar 132b, forming a step relative to the rest of the first heat sink 12, and forming a recess 12x exposed as the surface of the insulating member 117 (see reference). Figure 11 Thus, the transformer rectifier block 11 is mounted on the negative side block 10 (see reference) with the busbar 132b and the mounting base plate 111 only in contact with the surface of the insulating member 117 and insulated from the first heat sink 12. Figure 11 ).

[0097] Next, the electrical and mechanical connections between the transformer 120, the conductive part 130, the rectifier element part 112 and the first heat sink 12 are configured as follows.

[0098] Regarding the connection between the transformer 120 and the conductive part 130, in particular, such as Figure 7 and Figure 10 As shown, taking the first sub-mounting substrate 111A as an example, it is configured as follows: The connection terminal 124a of the transformer 120 and the busbar 131a are electrically and mechanically connected by fastening via connection pin 137a; the connection terminal 124b and the busbar 131b are electrically and mechanically connected by fastening via connection pin 137b. The busbars 131a and 132a are electrically and mechanically connected by fastening via connection pin 133a passing through the first sub-mounting substrate 111A; the busbars 131b and 132b are electrically and mechanically connected by fastening via connection pin 133b passing through the first sub-mounting substrate 111A.

[0099] In addition, Figure 7 In the second sub-mounting substrate 111B, which is located on the back side and is not shown as a dead angle, the left and right sides of the first sub-conductive portion 130a and the second sub-conductive portion 130b are arranged in a state that is interchanged with that of the first sub-mounting substrate 111A. Therefore, in the second sub-mounting substrate 111B, the connection terminal 124a of the transformer 120 and the bus bar 131a are electrically and mechanically connected by fastening via the connection pin 137a, and the connection terminal 124b and the bus bar 131b are electrically and mechanically connected by fastening via the connection pin 137b. The bus bar 131a and the bus bar 132a are electrically and mechanically connected by fastening via the connection pin 133a that penetrates through the first sub-mounting substrate 111A, and the bus bar 131b and the bus bar 132b are electrically and mechanically connected by fastening via the connection pin 133b that penetrates through the first sub-mounting substrate 111A.

[0100] Next, regarding the connection between the conductive part 130 and the rectifier element part 112, as follows... Figure 9As shown, taking the rectifier element 121B1 at the right end of the rectifier element group 112B as an example, it is configured as follows. The drain electrode 112a, which is exposed to the opposing surface facing the surface 111F of the mounting substrate 111, and the bus bar 131b are electrically connected by joining through a conductive passage 134b that is configured to extend from the surface 111F of the mounting substrate 111 to the back surface 111R.

[0101] Next, regarding the electrical connection between the rectifier element 112 and the first heat sink 12, as follows... Figure 9 As shown, taking the rectifier element 121B1 at the right end of the rectifier element group 112B as an example, it is configured as follows. The source electrode 112b, which is configured to extend downward along the surface 111F of the mounting substrate 111, is electrically connected to the first heat sink 12 by means of a conductive connection pin 136b, which is configured to extend from the surface 111F of the mounting substrate 111 to the back surface 111R, and a conductive connection member 135b electrically connected to the connection pin 136b.

[0102] Furthermore, a rectifier element section 112 may also be provided between the rectifier element section 112 and the first heat sink 12. Figures 7-10 The smoothing circuit is not shown in the figure.

[0103] The electrical connection between the rectifier element section 112 and the drive circuit 113 is configured as follows. Specifically, as... Figure 7 As shown, the first sub-driving circuit 113a is electrically connected to the gate electrodes of the plurality of rectifier elements constituting the rectifier element group 112A on the surface 111F of the mounting substrate 111 via gate wiring 114a, which is formed as printed wiring on the mounting substrate 111.

[0104] Similarly, the second sub-driving circuit 113b is electrically connected to the gate electrodes of the plurality of rectifier elements constituting the rectifier element group 112B on the surface 111F of the mounting substrate 111 via gate wiring 114b, which is formed as printed wiring on the mounting substrate 111.

[0105] In the transformer rectifier block 11 having the above configuration, when viewed from above along the mounting base plate 111, the transformer 120 and the mounting base plate 111 are arranged opposite each other with the busbar 131b sandwiched in between. In other words, the transformer 120 is adjacent to the mounting base plate 111 across the busbar 131b, which serves as an electrical path.

[0106] Figures 7-10 The conductive part 130 shown is in Figure 6The secondary DC-DC converter 300 of the DC power supply device shown corresponds to the following parts: busbars 131a and 132a and connection pin 133a correspond to the electrical path 314a between the secondary side terminal 311a2 of the positive terminal of transformer 311 and the mounting plate 313; busbars 131b and 132b and connection pin 133b correspond to the electrical path 314b between the secondary side terminal 311b2 of the negative terminal of transformer 311 and the mounting plate 313.

[0107] Figures 7-10 The connecting member 135a and connecting pin 136a shown are equivalent to Figure 6 The electrical path 315a shown is from the source electrode of the positive side rectifier 312A to the connection point CG. The connecting member 135b and the connecting pin 136b are equivalent to the electrical path 315b from the source electrode of the negative side rectifier 312B to the connection point CG.

[0108] Figures 7-10 The busbar 132a and (not shown) passage 134a shown are equivalent to Figure 6 The electrical path 318a shown is from electrical path 314a to the drain electrode of the positive side rectifier 312A of rectifier 312. Busbar 132b and passage 134b correspond to electrical path 318b from electrical path 314b to the drain electrode of the negative side rectifier 312B of rectifier 312.

[0109] Figures 1-3 , Figure 5 The first heat sink 12 and the first terminal busbar 14 shown are equivalent to Figure 6 The electrical path 316 between the connection point CG shown and the connection terminal OdN on the negative side of the output Od2 of the secondary DC-DC converter 300. Figures 1-3 , Figure 5 The second heat sink 22 and the second terminal busbar 24 shown are equivalent to Figure 6 The electrical path 317 between the center tap 311c of the transformer 311 shown and the connection terminal OdP on the positive side of the output Od2 of the secondary DC-DC converter 300.

[0110] and then, Figure 7 , Figure 9 The gate wiring 114a shown, which connects the first sub-drive circuit 113a of drive circuit 113 to the rectifier element group 112A, is equivalent to the gate wiring 320a between drive circuit 319 and positive side rectifier element 312A. Figure 7 , Figure 9The gate wiring 114b shown, which connects the second sub-drive circuit 113b of drive circuit 113 to rectifier element group 112B, is equivalent to Figure 6 The gate wiring 320b between the drive circuit 319 shown and the negative side rectifier element 312B.

[0111] The negative side block 10 and positive side block 20, on which the transformer rectifier block 11 is mounted, are integrally fixed by brackets 30a and 30b, which serve as a pair of supports. Specifically, bracket 30a is disposed across and exposed on the first heat sink 12 of the negative side block 10 and the second heat sink 22 of the positive side block 20, which are adjacent to and exposed on the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11, and is fastened to the first heat sink 12 and the second heat sink 22, respectively. Similarly, bracket 30b is disposed across and exposed on the first heat sink 12 of the negative side block 10 and the second heat sink 22 of the positive side block 20, which are adjacent to and exposed on the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11, and is fastened to the first heat sink 12 and the second heat sink 22, respectively.

[0112] Furthermore, the transformer 120 of the first sub-transformer rectifier block 11A is fixed to the positive side block 20 via bracket 31a. Similarly, the transformer 120 of the second sub-transformer rectifier block 11B, the transformer 120 of the third sub-transformer rectifier block 11C, and the transformer 120 of the fourth sub-transformer rectifier block 11D are respectively fixed to the positive side block 20 via bracket 31b, bracket 31c, and bracket 31d.

[0113] Thus, the transformers 120 contained in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11 are all installed in a manner that is thermally connected to the second heat sink 22.

[0114] In the DC-DC converter 1, the first sub-rectifier block 11A and the second sub-rectifier block 11B, located on the upper side, are arranged left and right along the wiring AL of the rectifier element section 112 with the transformer 120 above them, respectively. The third sub-rectifier block 11C and the fourth sub-rectifier block 11D, located on the lower side, are arranged left and right along the wiring AL of the rectifier element section 112 with the transformer 120 below them, respectively. In other words, the pair of blocks, the first sub-rectifier block 11A on the upper side and the third sub-rectifier block 11C on the lower side, and the second sub-rectifier block 11B on the upper side and the fourth sub-rectifier block 11D on the lower side, are arranged with the mounting substrate 111 facing each other.

[0115] In this configuration, each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier block 11D is an example of a sub-structure of the present invention. The arrangement of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and the arrangement of the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D, are examples of the arrangement of the transformer and rectifier element mounting structure of the present invention. Furthermore, the configuration of the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C, and the configuration of the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D, are examples of the arrangement of the transformer and rectifier element mounting structure of the present invention.

[0116] In the DC-DC converter 1 according to the embodiment of the present invention having the configuration as described above, the installation structure of the transformer and rectifier element in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11D constituting the transformer rectifier block 11 is configured as follows: The transformer 120 is positioned opposite the busbar AL of the rectifier element section 112, with busbars 131a and 131b sandwiched in the middle. The transformer 120 and the rectifier element section 112 are connected to the busbars 131a and 131b, which extend toward the busbar AL of the rectifier element section 112 in a direction substantially orthogonal to it. Thus, the electrical path connecting the connection terminal 124b and each of the plurality of rectifier elements constituting the rectifier element section 112 is formed as a straight line of substantially the same length with respect to each of the plurality of rectifier elements.

[0117] This means that the electrical path between the transformer 120 and each of the multiple rectifier elements in the rectifier element section 112, i.e. Figure 6 The electrical path 314a between the secondary side terminal 311a2 of the positive terminal of the transformer 311 and the mounting plate 313, and the electrical path 314b between the secondary side terminal 311b2 of the negative terminal of the transformer 311 and the mounting plate 313 in the secondary DC-DC converter section 300 of the DC power supply device shown are minimized relative to each of the rectifier elements 312A on the positive terminal side and 312B on the negative terminal side of the rectifier element 312.

[0118] As a result, losses in the transformer 120, the rectifier element section 112, and the busbar 131b, which serves as the electrical path, are reduced, thereby improving the conversion efficiency of the rectifier element section 112. Furthermore, by suppressing heat generation in the transformer 120, the rectifier element section 112, and the busbar 131b, which serves as the electrical path, a high-efficiency DC-DC converter and a DC power supply device equipped with it, suitable for handling high-current DC power supplies, can be obtained.

[0119] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the mounting structure of the transformer and rectifier element in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11 is configured as follows: The transformer 120 and the mounting plate 111 are arranged opposite each other with busbars 131a and 131b sandwiched in between, so that the transformer 120 is adjacent to the mounting plate 111 across the busbars 131a and 131b, which serve as electrical paths.

[0120] Therefore, the electrical paths of the transformer 120 and each of the multiple rectifier elements in the rectifier element section 112 are close, reducing losses in the transformer 120, the rectifier element section 112, and the busbars 131a and 131b that form the electrical paths, thereby improving the conversion efficiency of the rectifier element section 112. Furthermore, by suppressing heat generation in the transformer 120, the rectifier element section 112, and the busbars 131b that form the electrical paths, a high-efficiency DC-DC converter suitable for handling high-current DC power supplies and a DC power supply equipped with it can be obtained.

[0121] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier element in the transformer rectifier block 11 are configured as follows: a first heat sink 12 is provided, which is electrically connected to the rectifier element section 112 via the mounting plate 111, and extends out in a direction substantially parallel to the busbar AL to form a conductive path.

[0122] Therefore, the conductive path of the DC-DC converter 1, which is assembled with the transformer and rectifier components, is... Figure 6 The electrical path 316 between the connection point CG and the negative terminal OdN of the output Od2 of the secondary DC-DC converter section 300 of the DC power supply device shown can be configured with a short distance while ensuring heat dissipation. Furthermore, a high-efficiency DC-DC converter suitable for handling high currents and a DC power supply device equipped with it can be obtained.

[0123] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier element in the transformer rectifier block 11 are configured as follows: A second heat sink 22 is provided, which is electrically connected to the intermediate terminal 122c of the secondary side of the transformer 120, which is a polarity different from the electrical path connecting the transformer 120 and the rectifier element section 112, and extends out in a direction substantially parallel to the busbar AL to form a conductive path.

[0124] Therefore, the conductive path of the DC-DC converter 1, which is assembled with the transformer and rectifier components, is... Figure 6 The electrical path 315 in the secondary DC-DC converter section 300 of the DC power supply device shown, from the source electrode of the rectifier element 312B on the negative side of the rectifier element 312 to the connection point CG, can be configured with a short distance while ensuring heat dissipation. Furthermore, a high-efficiency DC-DC converter suitable for handling high current DC power supplies and a DC power supply device equipped with it can be obtained.

[0125] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier element in the transformer-rectifier block 11 are configured as follows. That is, the transformers 120 included in each of the first sub-transformer-rectifier blocks 11A to the fourth sub-transformer-rectifier blocks 11 constituting the transformer-rectifier block 11 are all thermally connected to the second heat sink 22.

[0126] This allows the heat generated by the transformer 120 to be conducted to the second heat sink 22, efficiently cooling the transformer 120. Furthermore, it enables the acquisition of a high-efficiency DC-DC converter suitable for handling high-current DC power supplies, and a DC power supply equipped with such a converter.

[0127] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier element in the transformer-rectifier block 11 are configured as follows: the first sub-mounting substrate 111A and the second sub-mounting substrate 111B in the transformer-rectifier block 11 are fixed in contact with the main surface of the first heat sink 12, and a rectifier element portion 112 is mounted on each of the first sub-mounting substrate 111A and the second sub-mounting substrate 111B.

[0128] Therefore, in the transformer rectifier block 11, a large number of rectifier elements constituting the rectifier element section 112 can be installed in a space-saving manner, which can effectively improve the installation density.

[0129] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the installation structure of the transformer and rectifier element in the transformer-rectifier block 11 is configured as follows. That is, when the dimension of the wiring AL along the rectifier element section 112 is set as the width dimension, the width (second side) of the busbars 131a and 131b on the rectifier element section 112 side in the transformer-rectifier block 11 is greater than the width (first side) on the connection terminal 124b side of the transformer 120.

[0130] As a result, the heat dissipation of busbars 131a and 131b is improved, which can suppress the heat generation of the transformer 120, the rectifier element section 112, and the busbars 131a and 131b, which are the physical entities of the electrical path, thereby improving the conversion efficiency of the rectifier element section 112. Furthermore, it is possible to obtain a high-efficiency DC-DC converter and a DC power supply device equipped with it that are suitable for handling high-current DC power supplies.

[0131] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier elements in the transformer rectifier block 11 are configured as follows. That is, a refrigerant pipe 13 serving as a cooling path for refrigerant circulation is provided inside the first heat sink 12 of the negative side block 10.

[0132] This allows for improved cooling efficiency of the DC-DC converter 1 while simultaneously saving space around the first heat sink 12, which also serves as a conductive circuit.

[0133] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier elements in the transformer-rectifier block 11 are configured as follows. That is, a refrigerant pipe 23 serving as a cooling path for refrigerant circulation is provided inside the second heat sink 22 of the positive electrode side block 20.

[0134] This allows for improved cooling efficiency of the DC-DC converter 1 while simultaneously saving space around the second heat sink 22, which also serves as a conductive circuit. Furthermore, it enables the development of a high-efficiency DC-DC converter suitable for handling high-current DC power supplies, and a DC power supply equipped with it.

[0135] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier element in the transformer-rectifier block 11 are configured as follows. That is, the transformer-rectifier block 11 has four sub-transformer-rectifier blocks of the same configuration, namely, the first sub-transformer-rectifier block 11A to the fourth sub-transformer-rectifier block 11D, the first sub-transformer-rectifier block 11A, the second sub-transformer-rectifier block 11B, the third sub-transformer-rectifier block 11C, and the fourth sub-transformer-rectifier block 11D are arranged left and right along the wiring line AL of the rectifier element section 112.

[0136] Therefore, it is possible to construct an arrangement of the transformer and rectifier mounting structures as two pairs of substructures, each having a mounting structure of the transformer and rectifier of the present invention, thereby minimizing the electrical paths between the multiple substructures and achieving an electrical path layout with excellent transmission efficiency. Furthermore, it is possible to obtain a high-efficiency DC-DC converter suitable for handling high-current DC power supplies and a DC power supply device equipped with it.

[0137] Next, in the DC-DC converter 1 according to the embodiment of the present invention, the transformer and rectifier elements in the transformer-rectifier block 11 are configured as follows. That is, the transformer-rectifier block 11 has four sub-transformer-rectifier blocks of the same configuration: the first sub-transformer-rectifier block 11A to the fourth sub-transformer-rectifier block 11D, the first sub-transformer-rectifier block 11A located on the upper side and the third sub-transformer-rectifier block 11C located on the lower side, and the second sub-transformer-rectifier block 11B located on the upper side and the fourth sub-transformer-rectifier block 11D located on the lower side, arranged with the mounting base 111 facing each other.

[0138] Therefore, it is possible to construct an arrangement of the transformer and rectifier mounting structures as two pairs of substructures, each having a mounting structure of the transformer and rectifier of the present invention, thereby minimizing the electrical paths between the multiple substructures and achieving an electrical path layout with excellent transmission efficiency. Furthermore, it is possible to obtain a high-efficiency DC-DC converter suitable for handling high-current DC power supplies and a DC power supply device equipped with it.

[0139] Furthermore, in the DC-DC converter 1 according to the embodiment of the present invention, the installation structure of the transformer and rectifier element in the transformer-rectifier block 11 is configured as follows. That is, in the positive side block 20, connection terminals 21A, 21B, 21C and 21D for electrical connection with the center tap of the transformer 120 of the transformer-rectifier block 11 are protruding from the surface of the second heat sink 22, and a gap C is formed between the transformer-rectifier block 11 and the second heat sink 22 in the DC-DC converter 1.

[0140] Therefore, the gap C functions as an air-cooling circuit, enabling air cooling of the transformer rectifier block 11 and the second heat sink 22, thereby improving the cooling efficiency of these components. Furthermore, it becomes possible to obtain a high-efficiency DC-DC converter suitable for handling high-current DC power supplies, and a DC power supply equipped with it.

[0141] As described above, according to the present invention, it is possible to provide a mounting structure for a transformer and rectifier elements that is suitable for improving the conversion efficiency of the rectifier elements, thereby enabling a high-efficiency DC-DC converter suitable for handling high-current DC power supply devices.

[0142] (variant examples, etc.) In the installation structure of the transformer and rectifier element in the transformer rectifier block 11 according to the embodiment of the present invention, the transformer 120 and the rectifier element section 112 are connected by busbars 131a and 131b extending in a direction substantially orthogonal to the busbars AL relative to the rectifier element section 112, thereby connecting the transformer's connection terminal 124a or connection terminal 124b with each of the plurality of rectifier elements constituting the rectifier element section 112. The electrical path is formed in a direction substantially orthogonal to the line segment, i.e., the busbar AL, arranged along the arrangement of the plurality of rectifier elements when viewed from above the mounting plate. However, the busbar AL, which is the line arranged along the arrangement of the plurality of rectifier elements, is not limited to a line segment.

[0143] That is, the mounting structure of the transformer and rectifier element of the present invention is only required that the electrical path connecting the transformer and each of the multiple rectifier elements mounted on the mounting base is formed in a way that the straight lines with respect to each of the multiple rectifier elements are substantially of the same length, and is formed in a way that is substantially orthogonal to the line along the arrangement of the multiple rectifier elements, i.e., the wiring line AL, when viewed from above the mounting base, and is not limited by the specific arrangement of the multiple rectifier elements, or in other words, the specific shape of the wiring line AL.

[0144] For example, Figure 7 The installation structure of the transformer and rectifier components in the transformer-rectifier block 11 shown is as follows: Figure 13 As illustrated, the electrical path EP connecting the transformer 120 and the various rectifier elements of the rectifier element section 112 is formed approximately orthogonally to the arrangement of the various rectifier elements of the plurality of rectifier elements 112x, i.e., the wiring AL as a line segment, thereby forming a straight line of substantially the same length. Furthermore, in Figure 13 In the figure, transformer 120 is configured opposite to a plane containing wiring AL, and is orthogonal to a plane shown in the figure that corresponds to the plane along the mounting substrate.

[0145] On the other hand, the installation structure of transformers and rectifier components can also be as follows: Figure 12 As shown in the schematic diagram, the individual rectifiers of the plurality of rectifier element sections 112x are arranged in an arc shape centered on the connection terminal 122x of the transformer 120. In this case, the electrical path EP is formed by the radius of the arc, which is approximately orthogonal to the wiring AL, thus forming a straight line of substantially the same length with respect to the individual rectifiers of the plurality of rectifier element sections 112x. Furthermore, in Figure 12 In the figure, transformer 120 is configured opposite to a curved surface containing wiring AL and orthogonal to a plane shown in the figure that is equivalent to the plane along the mounting substrate, and has an arc-shaped cross-section.

[0146] Furthermore, in the installation structure of the transformer and rectifier elements in the transformer-rectifier block 11 according to the embodiment of the present invention, the electrical path of the connecting terminal 124a or connecting terminal 124b of the transformer and each of the plurality of rectifier elements of the rectifier element section 112 is formed in an orientation that is substantially orthogonal to the wiring AL of the rectifier element section 112. However, this electrical path can also be as follows: Figure 14 As shown in the schematic diagram, it is formed to cross the wiring AL of the rectifier element section 112 at an arbitrary angle.

[0147] Furthermore, in the above descriptions, the electrical path connecting the transformer and each of the multiple rectifiers constituting the rectifier elements is formed such that, in a top view of the mounting substrate, it intersects with respect to the line AL along the arrangement of the multiple rectifiers, and the transformer is arranged opposite to the surface containing the line AL. However, in the mounting structure of the transformer and rectifier elements of the present invention, as long as the electrical path connecting the transformer and each of the multiple rectifiers is formed as a straight line of approximately the same length with respect to each of the multiple rectifiers, it is not limited by the specific configuration of the transformer and the multiple rectifiers.

[0148] Next, in the transformer rectifier block 11 of the DC-DC converter 1 according to the embodiment of the present invention, as an example of the arrangement structure of the transformer and rectifier element mounting structure of the present invention, it is set as an example of the substructure of the present invention, in which the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D with the same configuration are arranged left and right along the wiring line AL of the rectifier element section 112. However, the number of substructures arranged along the wiring line AL of the rectifier element can be single or any number of them.

[0149] Next, regarding the busbars 131a and 131b in the transformer rectifier block 11 of the DC-DC converter 1 according to the embodiments of the present invention, when the dimension of the wiring AL along the rectifier element section 112 is set as the width dimension, the width dimension (second side) on the rectifier element section 112 side is larger than the width dimension (first side) on the transformer 120 connection terminal 124b side, but the dimension of the second side may also be smaller than the dimension of the first side. This configuration is suitable when the width dimension of the connection terminal 124b is larger than the width dimension of the wiring AL on the rectifier element section 112 side.

[0150] Next, in the transformer rectifier block 11 of the DC-DC converter 1 according to the embodiment of the present invention, the mounting substrate 111 of the circuit section 110 is composed of a first sub-mounting substrate 111A exposed to the surface side in the DC-DC converter 1 and a second sub-mounting substrate 111B facing the second heat sink 22 of the positive electrode block 20, but it may also be configured as a single mounting substrate.

[0151] Next, in the above description, the installation structure of the transformer and rectifier element of the present invention is incorporated into the DC-DC converter 1, which is the final stage of the DC power supply device. However, the present invention can also be a DC power supply unit that outputs DC power from the transformer and rectifier element. Therefore, the present invention can also be incorporated into an AC-DC converter, or it can be implemented as an AC-DC converter.

[0152] Next, in the above description, the installation structure of the transformer and rectifier element of the present invention is configured as a synchronous full-wave rectifier circuit. However, the present invention can be configured for any rectifier circuit having a transformer and rectifier element, and is not limited to half-wave or full-wave rectification, synchronous or asynchronous rectification, or other specific rectification methods. Furthermore, it can also be used in ordinary transformers without center taps, and in rectifier circuits using diodes as rectifier elements, without being limited by the specific configuration, type, number, etc. of the transformer and rectifier element.

[0153] Next, in the above description, the installation structure of the transformer and rectifier element of the present invention is provided on the negative potential side in the DC-DC converter included in the DC power supply device, but it can also be provided on the positive potential side. In short, the present invention can be configured for any rectifier circuit having a transformer and rectifier element, and is not limited by the polarity of the wiring in the rectifier circuit.

[0154] As described above, embodiments of the present invention have been disclosed in the description, but the present invention is not limited thereto.

[0155] That is, various changes can be made to the above-described embodiments and variations in terms of mechanism, shape, material, quantity, position or configuration without departing from the technical concept and purpose of the present invention, and these are all included in the present invention. Explanation of reference numerals in the attached figures

[0156] 1DC-DC converter 10 Negative electrode side block 11 Transformer Rectifier Block 11A, 310A First Sub-Transformer Rectifier Block 11B, 310B second sub-transformer rectifier block 11C, 310C third sub-transformer rectifier block 11D, 310D fourth sub-transformer rectifier block 12 First heat sink 12x recess 13, 23 refrigerant piping 14 First terminal busbar 14E, 24E end 15, 25, 135a, 135b connecting components 20 positive electrode side blocks 21A, 21B, 21C, 21D, 21A~21D, 122x connection terminals 22 Second heat sink 22a First heat sink 22b Second son heat sink 23a First refrigerant piping 23b Second refrigerant piping 24 Second terminal busbar 30a, 30b, 31a, 31b, 31c, 31d brackets 100AC-DC converter 110 Circuit Department 111, 313 mounting base 111A First Sub-mounting Board 111B Second Sub-mounting Board 111F surface 111R Back 112, 112x Rectifier Components 112A, 112B rectifier element group 112a Drain electrode 112b source electrode 112c gate electrode 113, 319 drive circuit 113a First Sub-Driver Circuit 113b Second Sub-Driver Circuit 114a, 114b, 320a, 320b grid wiring 117 Insulating Components 120, 311 transformers 121 Primary Side Coil 121B1, 312 rectifier element 121a Primary side start 121b Primary-side terminal 122 secondary coil 122a, 122b secondary side start end 122c Secondary side middle end 123 PQ core 124a, 124b, 124c are connected to terminals 130 Conductive Part 130a First Sub-Conducting Part 130b Second Sub-Conducting Section 131a, 131b, 132a, 132b busbars 133a, 133b connection pins 134a, 134b passage 136a, 136b connection pins 200 Primary DC-DC Converter 300 Secondary DC-DC Converter 311a1, 311b1 primary side ends 311a2, 311b2 secondary side ends 311c center tap 312A Positive Side Rectifier 312B Negative-side Rectifier Component

Claims

1. An installation structure for a transformer and rectifier element, comprising: Transformer; and Multiple rectifier elements are connected to the transformer. The electrical path connecting the transformer and the plurality of rectifier elements is formed as a straight line of approximately the same length about each of the plurality of rectifier elements.

2. The installation structure of the transformer and rectifier element according to claim 1, wherein, The plurality of rectifier elements are mounted on a mounting substrate. The electrical path is formed in a top view of the mounting substrate, intersecting with the lines, i.e., the wiring, arranged along the arrangement of the plurality of rectifier elements. The transformer is configured opposite to the surface containing the busbar.

3. The installation structure of the transformer and rectifier element according to claim 2, wherein, The wiring is formed into line segments. The electrical path is formed in a generally orthogonal orientation relative to the cabling. The surface containing the wiring is formed as a plane.

4. The installation structure of the transformer and rectifier element according to claim 2, wherein, The transformer is adjacent to the mounting base plate across the electrical path.

5. The installation structure of the transformer and rectifier element according to claim 3, wherein, It has a first heat sink that is electrically connected to the plurality of rectifier elements via the mounting substrate and extends in a direction generally parallel to the wiring harness to form a conductive path.

6. The installation structure of the transformer and rectifier element according to claim 3, wherein, It has a second heat sink, which is connected to the output side of the transformer, which is different in polarity from the electrical path connecting the transformer and the plurality of rectifier elements, and extends out in a direction generally parallel to the busbar to form a conductive path.

7. The installation structure of the transformer and rectifier element according to claim 6, wherein, The transformer is mounted on the second heat sink.

8. The installation structure of the transformer and rectifier element according to claim 5, wherein, The mounting base plate has: The first sub-mounting substrate is fixed to a main surface of the first heat sink; and The second sub-mounting substrate is fixed to the other main surface of the first heat sink. The plurality of rectifier elements are mounted on each of the first sub-mounting substrate and the second sub-mounting substrate.

9. The installation structure of the transformer and rectifier element according to claim 5 or 6, wherein, The electrical path is formed as a busbar that electrically connects the transformer to the plurality of rectifier elements. Regarding the dimensions of the busbar along the sides of the busbar, the dimensions of the second side on the plurality of rectifier element side are greater than or less than the dimensions of the first side on the transformer side.

10. The installation structure of the transformer and rectifier element according to claim 5, wherein, It has a cooling path located inside the first heat sink for the passage of refrigerant.

11. The installation structure of the transformer and rectifier element according to claim 6, wherein, It has a cooling channel located inside the second heat sink for the passage of refrigerant.

12. An arrangement structure for mounting a transformer and rectifier components. The installation structure of the transformer and rectifier element as described in claim 3 is included as a sub-structure. The substructures are arranged along the wiring.

13. An arrangement structure for mounting a transformer and rectifier components. The sub-structure includes at least one pair of mounting structures for the transformer and rectifier elements as described in claim 2. In a pair of said sub-constructions, the mounting substrates are each arranged opposite to each other.

14. A DC power supply unit, An arrangement having the mounting structure of the transformer and rectifier components as described in claim 12 or 13. The output from the mounting structure of the transformer and rectifier elements is used as the DC output.

15. A DC power supply device, It has multiple DC power supply units as described in claim 14, The sum of the outputs of each of the DC power supply units is output.

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