Power conversion device and inductor

Abstract

The application provides a power conversion device and an inductor. It relates to the technical field of power conversion devices. The power conversion device comprises a shell, an inductor and a circuit board. The inductor comprises a winding, a bearing plate, a support block and a conductive piece. The circuit board is arranged on one side of the bearing plate along the thickness direction of the bearing plate. At least one end of the winding is arranged between the circuit board and the bearing plate. The support block is arranged on the side of the bearing plate facing the circuit board, and the support block is arranged to extend towards the circuit board along the thickness direction of the bearing plate. The conductive piece is arranged between the bearing plate and the circuit board. One end of the conductive piece is fixedly connected with the circuit board, and the other end of the conductive piece is fixedly connected with the winding. The two ends of the conductive piece are fixed to the support block. In this way, the force exerted by the circuit board on the conductive piece is at least partially transmitted to the support block, the force transmitted to the connection between the conductive piece and the winding is reduced, and the damage caused by the force to the connection strength of the conductive piece and the winding is reduced.

Description

Technical Field

[0001] This application relates to the field of power conversion equipment technology, and in particular to a power conversion device and an inductor. Background Technology

[0002] Inductors are inevitably present in power conversion devices. Inductors mainly play key roles in power conversion devices such as filtering, voltage regulation, energy storage, and energy transmission, ensuring that the power conversion device can efficiently and stably convert DC power into AC power.

[0003] In related technologies, the windings of an inductor need to be connected to a circuit board via an adapter bus or other means. Specifically, one end of the adapter bus is connected to one end of the inductor, and the other end of the adapter bus is connected to the circuit board. However, due to processing errors or assembly errors, there may be errors in the distance between the adapter bus and the circuit board. When the adapter bus is connected to the circuit board, the circuit board will apply external force to the bus, causing damage to the connection between the adapter bus and the inductor. Summary of the Invention

[0004] This application provides a power conversion device and an inductor. In this power conversion device, a conductive element is fixed to a support block at any position between its two ends, so that the force exerted by the circuit board on the conductive element is at least partially transmitted to the support block. This reduces the force transmitted to the connection between the conductive element and the winding, thereby reducing the damage to the connection strength of the conductive element and the winding caused by the force.

[0005] To achieve the above objectives, the embodiments of this application adopt the following technical solutions: In a first aspect, embodiments of this application provide a power conversion device, which includes a housing, an inductor, and a circuit board, with the circuit board disposed within the housing; wherein the inductor includes a winding, a carrier plate, a support block, and a conductive element; the circuit board is disposed on one side of the carrier plate along its thickness direction; at least one end of the winding is disposed between the circuit board and the carrier plate; the support block is disposed on the side of the carrier plate facing the circuit board, and extends toward the circuit board along the thickness direction of the carrier plate; the conductive element is disposed between the carrier plate and the circuit board, one end of the conductive element is fixedly connected to the circuit board, the other end of the conductive element is fixedly connected to the winding, and both ends of the conductive element are fixed to the support block.

[0006] Based on the power conversion device provided in this application, it is understood that each part in industrial manufacturing has an allowable tolerance range. However, the cumulative tolerances of multiple parts in the assembly direction lead to a deviation from the design expectation in the final mating state. In the power conversion device of this application, windings, a carrier plate, a support block, and conductive components are assembled to form an inductor, and then the inductor and a circuit board are connected. The cumulative tolerances of the windings, carrier plate, support block, conductive components, and circuit board can easily cause the mating state between the conductive components and the circuit board to deviate from the design expectation during the assembly of the inductor and the circuit board; that is, assembly tolerances appear between the conductive components and the circuit board during the assembly of the inductor and the circuit board. Therefore, to achieve the connection between the circuit board and the conductive components, the conductive components need to deform to correct the assembly tolerances between them. For the conductive components to deform, they need to be subjected to a force. When the circuit board and the conductive components are connected, the circuit board can apply a force to the conductive components, causing them to deform. However, the force applied by the circuit board to the conductive component will be transmitted from the end where the conductive component is connected to the circuit board to the end where the conductive component is connected to the winding. When this force is transmitted to the end where the conductive component is connected to the winding, the end where the conductive component is connected to the winding will also deform, affecting the connection strength between the conductive component and the winding.

[0007] Therefore, in this application, if the conductive element is fixed to the support block at any position between its two ends, the force exerted by the circuit board on the conductive element will be at least partially transmitted to the support block after reaching the connection point between the conductive element and the support block. Thus, no force or only a small portion of the force will be transmitted to the end where the conductive element is connected to the winding. That is, most of the force exerted by the circuit board on the conductive element is limited between the end of the conductive element connected to the circuit board and the position where the elastic circuit board is fixed to the support block, with only a small portion or no force transmitted to the end where the conductive element is connected to the winding. Similarly, the conductive element deforms from the end connected to the circuit board, but because the conductive element is fixed to the support block between its two ends, at least a portion of the deformation is also limited between the end connected to the circuit board and the position fixed to the support block. The end where the conductive element is connected to the winding experiences only a small amount of deformation or no deformation. In this way, the end where the conductive element is connected to the winding is not subjected to force or only bears a small amount of force, and the end where the conductive element is connected to the winding also does not deform or experiences only a small amount of deformation, reducing the damage to the connection strength between the conductive element and the winding caused by the force.

[0008] In some feasible implementations, a through hole is provided between the two ends of the conductive element along the extension path of the conductive element; a first fastener is provided on the support block; the power conversion device also includes a first fixing member, which passes through the through hole and is fixedly connected to the first fastener.

[0009] In this feasible method, a first fastener is provided on the support block, and a first fixing member passes through a through hole provided on the conductive member and is connected to the first fastener. The first fixing member can firmly press the conductive member onto the support block. The force applied by the circuit board to the conductive member is limited between the end of the conductive member connected to the circuit board and the position fixed to the support block. The part of the conductive member between the end connected to the circuit board and the position fixed to the support block deforms, completely absorbing the force applied by the circuit board to the conductive member. No force is transmitted to the part of the conductive member connected to the winding and the position fixed to the support block. Therefore, the part of the conductive member between the winding and the position fixed to the support block does not deform at all. The connection relationship between the conductive member and the winding is not affected by the force applied by the elastic circuit board to the conductive member, thus protecting the connection strength of the conductive member and the winding.

[0010] In some feasible implementations, the support block is equipped with a latch, which engages with the conductive element at any position between its two ends along the extension path of the conductive element.

[0011] In this feasible method, a buckle is provided on the support block, and the conductive element is snapped into the buckle at any position between its two ends. The force exerted by the circuit board on the conductive element is at least partially limited to the portion between the end of the conductive element connected to the circuit board and the position fixed to the support block. Thus, the portion of the conductive element between the connection winding and the position fixed to the support block bears part or no force exerted by the circuit board on the conductive element, thereby reducing or completely eliminating the damage caused by the force to the connection strength of the conductive element and the winding.

[0012] Furthermore, by securing the conductive component with clips, its structure remains unchanged. Most importantly, no holes are needed on the conductive component, thus preserving its effective cross-sectional area and ensuring efficient current transmission.

[0013] In some feasible implementations, a positioning hole is provided between the two ends of the conductive component along the extension path of the conductive component; a positioning pin is provided on the support block, and the positioning pin is inserted into the positioning hole.

[0014] In this feasible method, a positioning pin is provided on the support block, and a positioning hole that mates with the positioning pin is provided between the two ends of the conductive component. After the positioning pin is inserted into the positioning hole, the conductive component is fixed to the support block. The force exerted by the circuit board on the conductive component is limited to the part between the end of the conductive component connected to the circuit board and the positioning hole. The part of the conductive component between the connecting winding and the positioning hole bears part of the force exerted by the circuit board on the conductive component, reducing the damage to the connection strength of the conductive component and the winding caused by the force.

[0015] Furthermore, when assembling the conductive component onto the support block, it is only necessary to insert the positioning pin into the positioning hole to fix the conductive component onto the support block, making the assembly of the conductive component very convenient.

[0016] In some possible implementations, the conductive element includes a first segment, a second segment, and a third segment connected in sequence; the first segment is connected to a circuit board, extending in a direction parallel to the circuit board and disposed between the support block and the circuit board; the second segment is fixed to the support block; and the third segment is connected to a winding, extending toward the winding along the thickness direction of the carrier plate.

[0017] In this feasible configuration, the first segment is used to connect to the circuit board. Extending the first segment perpendicular to the thickness direction of the support plate allows for a larger overlap area between the first segment and the circuit board along the thickness direction of the support plate. This provides a larger area for the conductive component to connect with the circuit board, facilitating the connection between the conductive component and the circuit board. Furthermore, the first segment can move relative to the support block along the thickness direction of the support plate and parallel to the circuit board; that is, the first segment is not fixed and can move freely. This allows the first segment to move relative to the circuit board, facilitating the adjustment of the relative position between the first segment and the circuit board and simplifying the connection between them.

[0018] The third section is used to connect with the winding. Along the thickness direction of the bearing plate, the third section extends towards the winding to facilitate the connection between the conductive parts and the winding.

[0019] In some feasible implementations, a second groove is provided on the side of the support block facing the circuit board along the thickness direction of the support plate, and a second fastener is provided in the second groove. The second fastener is movable in the second groove along the depth direction of the second groove and in the direction parallel to the circuit board; and the sidewall of the second groove can restrict the rotation of the first fastener in the second groove; the power conversion device includes a second fixing member, which passes through the circuit board and the first section and is connected to the first fastener.

[0020] In this feasible configuration, the connector passes through the circuit board and the first segment before connecting to the first fastener. Thus, the second fastener and the second fixing member achieve the connection between the first segment and the circuit board. Since the second fastener can move within the second groove along its depth, the second fastener can move with the first segment as it moves towards or away from the circuit board. In the direction parallel to the circuit board, the second fastener can move within the second groove. When the first segment needs to be aligned with the circuit board and moves in the direction parallel to the circuit board, the second fastener can also move in the plane parallel to the circuit board, ensuring that the second fixing member aligns with the first fastener after passing through the circuit board and the first segment. Furthermore, the sidewall of the second groove restricts the rotation of the first fastener within the groove. When the connector and the second fastener are connected, it prevents the second fastener from rotating synchronously with the connector. For example, if the second fixing member is a bolt and the second fastener is a nut, the sidewall of the second groove restricts the rotation of the first fastener within the groove, allowing the bolt to rotate relative to the nut and complete the threaded connection.

[0021] In some possible implementations, the second segment has a bend, and the second segment is fixed to the support block at a position outside the bend.

[0022] In this feasible method, after the circuit board applies a force to the conductive component, stress concentration will occur at the bending position of the second segment. When the conductive component deforms, the deformation is mainly concentrated at the bending position. In this way, the deformation of the conductive component mainly occurs in the second segment of the conductive component, minimizing the deformation of the first and third segments. The deformation of the conductive component between the part connecting the winding and the part fixed to the support block is reduced, further reducing the damage of the force to the connection strength of the conductive component and the winding.

[0023] In some possible implementations, the second segment includes a first sub-segment and a second sub-segment connected in sequence, the end of the first sub-segment away from the second sub-segment being connected to the first segment, and the first sub-segment extending along the thickness direction of the bearing plate; the end of the second sub-segment away from the first segment being connected to the third segment, and the second sub-segment extending perpendicular to the thickness direction of the bearing plate; at least one of the first sub-segment and the second sub-segment is fixed to the support block.

[0024] In this feasible method, after the circuit board applies a force to the conductive element along the thickness direction of the carrier plate, the first segment extends along the thickness direction of the carrier plate. When the force applied by the circuit board to the end of the conductive element connected to the circuit board has a component force perpendicular to the thickness direction of the carrier plate, the first segment begins to deform around itself and the connection point of the second segment, and the deformation is greater the farther the first segment is from the second segment, in order to compensate for the processing error or assembly error of the power conversion device in the direction perpendicular to the thickness direction of the carrier plate, for example, the connection hole of the circuit board and the end of the conductive element near the circuit board are not aligned. When the force applied by the circuit board to the end of the conductive element connected to the circuit board has a component force parallel to the thickness direction of the carrier plate, the second segment begins to deform around itself and the connection point of the first segment, and the deformation is greater the farther the second segment is from the first segment, in order to compensate for the processing error or assembly error of the power conversion device in the direction parallel to the thickness direction of the carrier plate, for example, there is a gap between the circuit board and the end of the conductive element near the circuit board.

[0025] In some possible implementations, the side of the support block facing the circuit board includes a first platform and a second platform, which are connected by a first side; the first platform is parallel to a first segment, the first side is parallel to a first sub-segment, and the second platform is parallel to a second sub-segment; along the thickness direction of the bearing plate, the first segment is disposed between the first platform and the circuit board; the first sub-segment is fixedly connected to the first side, and / or the second sub-segment is fixedly connected to the second platform.

[0026] In this feasible method, the first segment is disposed between the first platform and the circuit board and fixed to the circuit board. In the thickness direction of the support plate, the first segment is close to the circuit board, which facilitates the connection between the first segment and the circuit board. The first sub-segment is fixed to the first side, and / or the second sub-segment is fixed to the second platform, both of which can achieve the goal of fixing the second segment to the support block. At the same time, the first sub-segment is parallel to the first side, the second segment is parallel to the second side, and the shape of the support block is set to correspond to the shape of the conductive component, so that the conductive component can fit against the surface of the support block, and the support block can better support the conductive component.

[0027] In some possible implementations, the conductive element includes an arc-shaped segment that protrudes away from the support block, and a second segment fixed to the support block at a position outside the arc-shaped segment.

[0028] In this feasible method, after the circuit board applies a force to the conductive component, the curved segment, due to its bending, will generate concentrated stress at the bending point when subjected to force. Therefore, when the conductive component deforms, the deformation of the conductive component is mainly concentrated at the position of the curved segment. In this way, the deformation generated by the conductive component is further concentrated between the end of the conductive component connected to the circuit board and the position fixed to the support block. The deformation generated by the conductive component between the part connected to the winding and the part fixed to the support block is reduced, further reducing the damage of the force to the connection strength of the conductive component and the winding.

[0029] In some feasible ways, the conductor is fixed to the support block near the winding along the extension path of the conductor.

[0030] In this feasible approach, the greater the distance between the position where the conductive component is fixed to the support block and the position where the conductive component connects to the circuit board, the longer the lever arm (taking the position where the conductive component is fixed to the support block as the rotation point, the connection point between the conductive component and the circuit board as the force point, and the lever arm as the perpendicular distance from the line of action of the force to the rotation axis). According to the torque formula T=F×r, where T is the torque, F is the force, and r is the length of the lever arm, a longer lever arm makes it easier for the conductive component to deform, thus absorbing the assembly tolerances and processing errors of the power conversion device. Simultaneously, according to the principle that action equals reaction, the reaction force exerted by the conductive component on the circuit board is also smaller, and the impact of the reaction force on the circuit board structure is also less.

[0031] In some feasible implementations, the power conversion device further includes an adapter, the other end of which is fixedly connected to the winding via the adapter; the adapter includes an integrally formed first connecting part and a second connecting part, the first connecting part being fixedly connected to the winding and the first connecting part being made of the same material as the winding; the second connecting part being fixedly connected to the conductive part and the second connecting part being made of the same material as the conductive part.

[0032] In this feasible method, the winding and the conductor are usually connected by welding. When the winding and the conductor are made of different materials, the connection strength after direct welding is very poor. If the first connecting part of the adapter is made of the same material as the winding, the connection strength after welding the winding and the first connecting part is stronger. If the second connecting part of the adapter is made of the same material as the conductor, the connection strength after welding the conductor and the second connecting part is stronger. Since the adapter is integrally set, the strength of the adapter is higher than that after welding two different materials, thus improving the connection strength between the conductor and the end of the winding.

[0033] In some feasible implementations, the conductive element is a conductive bus or conductive strip.

[0034] In this feasible method, the busbar, as a solid conductor, has a large cross-sectional area, which can stably carry and efficiently transmit large currents of hundreds to thousands of amperes, with low power loss. It is suitable for the transmission of large currents after the power conversion device converts DC to AC.

[0035] The conductive strip is woven from multiple layers of copper foil or multiple strands of copper wire. Its flexible structure can effectively compensate for processing or assembly errors. The circuit board cannot apply force to it, and it can also effectively absorb and compensate for vibrations, displacements and thermal expansion and contraction generated during equipment operation, preventing connection points from being damaged due to stress.

[0036] In some feasible ways, the conductive element and the winding are made of different materials, and the other end of the conductive element is directly connected to the winding.

[0037] In this feasible method, although the winding and the conductive component are made of different materials and have poor connection strength after direct welding, the two ends of the conductive component are fixed to the support block in this application. The deformation of the conductive component is limited to the end of the conductive component connected to the circuit board and the position where the conductive component is fixed to the support block. Even if the winding and the conductive component are made of different materials and are directly connected, the force applied by the circuit board to the conductive component cannot be transmitted along the conductive component to the end where the conductive component and the winding are connected. The connection strength between the winding and the conductive component can still be guaranteed, and the connection cost between the conductive component and the winding is saved.

[0038] In some feasible methods, the conductive material is copper, and the winding material is aluminum.

[0039] In this feasible approach, using aluminum as the winding material reduces winding costs. Furthermore, the lighter weight of aluminum inductors reduces the weight of the power conversion device. Copper conductors, with their excellent conductivity, can more quickly transfer direct current from the circuit board to the windings, and also more quickly transfer alternating current output from the windings to the circuit board.

[0040] In some feasible implementations, the inductor includes multiple windings, multiple conductive elements, and multiple support blocks; one end of each of the multiple conductive elements is connected to the circuit board, and the other end of each of the multiple conductive elements is connected to the corresponding winding, and the two support blocks corresponding to two adjacent windings are integrally set.

[0041] In this feasible approach, the two support blocks corresponding to the two windings are integrated into one unit, and one support block supports two conductor buses at the same time, which simplifies the structure of the inductor.

[0042] Secondly, embodiments of this application provide an inductor applied to a power conversion device having a circuit board. The inductor includes a winding, a carrier plate, a support block, and a conductive element. Along the thickness direction of the carrier plate, the circuit board is disposed on one side of the carrier plate. At least one end of the winding is disposed between the circuit board and the carrier plate. The support block is disposed on the side of the carrier plate facing the circuit board, and extends toward the circuit board along the thickness direction of the carrier plate. The conductive element is disposed between the carrier plate and the circuit board, one end of the conductive element is connected to the circuit board, the other end of the conductive element is connected to the winding, and the conductive element is fixed to the support block between its two ends.

[0043] Based on the inductor provided in the embodiments of this application, since the inductor is applied to the power conversion device, the effect of the inductor applied to the power conversion device can be referred to the effect of the power conversion device described above, and will not be repeated here. Attached Figure Description

[0044] Figure 1 This application provides a schematic diagram of the connection of a photovoltaic power station. Figure 2 A DC / AC circuit diagram provided for an embodiment of this application; Figure 3 An exploded structural diagram of a power conversion device, exemplified by an inverter, provided in an embodiment of this application; Figure 4 A schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 5 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 6 For support blocks, conductive parts and snap-fit ​​edges Figure 5 Sectional view of section AA; Figure 7 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 8A This is a schematic diagram of the structure of a conductive element provided in an embodiment of this application; Figure 8B This is a schematic diagram of another conductive element provided in an embodiment of this application; Figure 9 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 10 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 11 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 12 Schematic diagrams of various conductive components provided in the embodiments of this application; Figure 13 This is a schematic diagram of the structure of another conductive element provided in an embodiment of this application; Figure 14 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application; Figure 15 This application provides a schematic diagram of a conductive element connected to a winding via an adapter, as shown in the embodiments of the present application. Figure 16 A schematic diagram of another conductive element connected to a winding via an adapter, provided in an embodiment of this application; Figure 17 This is another schematic diagram of the connection between an inductor and a circuit board provided in an embodiment of this application.

[0045] Figure label: a. The thickness direction of the bearing plate; 100. Photovoltaic modules; 200. Inverters; 300. Energy storage cabinets; 400. Distribution boxes; 500. Electricity meters; 600. Power grid; 10. Outer shell; 11. Lower shell; 111. Receiving groove; 12. Upper cover; 20. Circuit board; 30. Inductor; 31. Support plate; 311. Clearance hole; 32. Support block; 321. Positioning pin; 322. Buckle; 3221. Elastic arm; 3222. Locking block; 323. First platform; 324. Second platform; 325. First side; 33. Conductive component; 331. Through hole; 333. First segment; 334. Second segment; 3341. First sub-segment; 3342. Second sub-segment; 335. Third segment; 336. Arc segment; 337. Positioning hole; 34. Winding; 35. Housing; 40A, First fastener; 40B, First fixing component; 50. Card ring; 60. Adapter; 61. First connecting part; 62. Second connecting part; 70A, Second fastener; 70B, Second fixing component; M1, first switching transistor; M2, second switching transistor; M3, third switching transistor; M4, fourth switching transistor; C, capacitor. Detailed Implementation

[0046] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0047] The terms "first," "second," and similar terms used in this article do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms "one" or "a" do not indicate a quantity limitation, but rather indicate the existence of at least one.

[0048] In the embodiments of this application, the terms "exemplarily" or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplarily" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design solutions. Specifically, the use of terms such as "exemplarily" or "for example" is intended to present the relevant concepts in a specific manner. In the description of the embodiments of this application, unless otherwise stated, "a plurality of" means two or more.

[0049] First, let me explain the technical terms used in this application: Eddy current loss refers to the phenomenon where a conductor generates a circular current (eddy current) due to electromagnetic induction in an alternating magnetic field, resulting in the conversion of electrical energy into heat energy. Conductive components such as copper foil and metal busbars on circuit boards may experience eddy current loss due to changes in the magnetic field during high-frequency signal transmission.

[0050] Alternating current (AC) refers to a current whose magnitude and direction change periodically with time; alternating magnetic field refers to a magnetic field whose magnitude and direction change with time. An alternating magnetic field is a magnetic field generated when alternating current is transmitted through a conductor. When the current is alternating current, the magnetic field generated will also change accordingly.

[0051] Inductive filtering utilizes impedance characteristics to impede the flow of high-frequency current, while allowing low-frequency or DC components to impede current surges through the inductor's self-inductance, thus suppressing high-frequency current.

[0052] The effective cross-sectional area of ​​a conductor refers to the equivalent cross-sectional area that actually participates in conduction under specific conditions (such as frequency, current distribution, etc.), and it may differ from the geometric cross-sectional area of ​​the conductor. In this application, the current flows from one end of the conductive element to the other, and the cross-section of the conductive element is its effective cross-sectional area.

[0053] Equivalent diameter is a geometric concept used to transform irregular shapes (such as non-circular cross-sections or irregular particles) into an ideal circular diameter with the same hydraulic or geometric properties, in order to facilitate analysis and calculation.

[0054] A power conversion device is an electronic device used to convert electrical energy from one form to another. For example, such a power conversion device can be an inverter, an uninterruptible power supply (UPS), an energy storage converter, or an on-board charger. The power conversion device of this application embodiment can be applied in fields such as site energy, residential energy storage, industrial and commercial energy storage, large-scale ground-mounted power station energy storage, or vehicle charging. This application embodiment uses an inverter as an example to illustrate the structure and function of the power conversion device.

[0055] Inverter 200 is suitable for photovoltaic (PV) power generation systems, which are systems that use photovoltaic modules 100 to absorb solar radiation energy for power generation. Figure 1 This is a connection diagram of a photovoltaic power station provided in an embodiment of this application. The following is in conjunction with... Figure 1 The function of the power conversion device is explained.

[0056] like Figure 1 As shown, the photovoltaic power station includes photovoltaic modules 100, inverters 200, energy storage cabinets 300, distribution boxes 400, electricity meters 500, and a power grid 600. Photovoltaic modules 100 convert solar energy into direct current (DC) and output it to the inverter 200. The inverter 200 converts DC into alternating current (AC) and outputs it to the distribution box 400; that is, the inverter 200 includes a DC / AC circuit for converting DC to AC. The energy storage cabinet 300 stores electrical energy or outputs the stored electrical energy in the form of AC; that is, the energy storage cabinet 300 of this application integrates a power conversion system (PCS). The distribution box 400 distributes electrical energy to the power grid 600 as needed through internal circuit breakers, switches, and other components. The electricity meter 500 is located between the distribution box 400 and the power grid 600, and its core function is to achieve accurate metering and monitoring of the bidirectional flow of electrical energy.

[0057] From the above Figure 1 The analysis shows that inverter 200 is used to convert DC power to AC power. Figure 2 This document provides a DC / AC circuit diagram for an embodiment of this application. The following is in conjunction with... Figure 2 A detailed explanation of the DC / AC circuit diagram is provided.

[0058] The DC / AC circuit diagram includes four switching transistors, two windings 34, and a capacitor C. The first switching transistor M1 and the fourth switching transistor M4 operate synchronously, as do the second switching transistor M2 and the third switching transistor M3. When the first switching transistor M1 and the fourth switching transistor M4 are on, the second switching transistor M2 and the third switching transistor M3 are off; conversely, when the first switching transistor M1 and the fourth switching transistor M4 are off, the second switching transistor M2 and the third switching transistor M3 are on, thus converting direct current into single-phase alternating current. The single-phase alternating current is then filtered by a filter circuit composed of windings 34 and capacitor C to remove high-frequency current, and a stable alternating current waveform is output from windings 34. Synchronous operation in this application refers to simultaneous on / off switching.

[0059] In some examples, capacitor C is a high-frequency filter capacitor C. A high-frequency filter capacitor C can provide a low-impedance path to ground for high-frequency noise (tens of MHz to GHz), instantly bypassing the high-frequency noise. For example, a multilayer ceramic capacitor (MLCC) C.

[0060] The switching transistor in this application embodiment can be a conventional transistor, an insulated-gate bipolar transistor (IGBT), or a metal-oxide-semiconductor field-effect transistor (MOSFET).

[0061] Figure 3 This is an exploded structural diagram of a power conversion device, exemplified by an inverter 200, provided as an embodiment of this application. The following is in conjunction with... Figure 3 The structure of the inverter 200 of this application will be described.

[0062] like Figure 3 As shown, the power conversion device includes a housing 10, an inductor 30, and a circuit board 20. The circuit board 20 is disposed inside the housing 10, and the inductor 30 and the circuit board 20 are electrically connected.

[0063] The housing 10 is used to protect the circuit board 20. In this application, the housing 10 can be a metal housing, a plastic housing, or a rubber housing; wherein, a metal housing has high strength and heat dissipation performance; a plastic housing is lightweight and low cost; and a rubber housing is suitable for harsh environments. Figure 3 As shown, in some examples, the housing 10 includes an upper cover 12 and a lower housing 11, the lower housing 11 having a receiving groove 111, the upper cover 12 and the lower housing 11 being connected and covering the opening of the receiving groove 111 to form a sealed receiving cavity.

[0064] It is understood that the circuit board 20 is disposed within the receiving groove 111 and protected by the outer casing 10. Furthermore, in some examples, the circuit board 20 in this application can be fixed to the lower casing 11. For example, the circuit board 20 and the lower casing 11 can be fixed by means of screw connection, adhesive bonding, or snap-fit ​​connection via clip 322.

[0065] Figure 2 The first switch M1, the second switch M2, the third switch M3, the fourth switch M4, and the two windings 34 shown in the diagram all need to be connected to the circuit board 20, and are electrically connected through the circuit board 20 to form a circuit. Figure 2 The DC / AC circuit diagram shown; in some examples, the circuit board 20 has printed lines, and the four switching transistors and two windings 34 are electrically connected through the printed lines. The circuit board 20 in this application can be a rigid circuit board (PCB) or a flexible printed circuit board (FPC).

[0066] Figure 4 This application provides a schematic diagram of the connection between an inductor 30 and a circuit board 20; it can be understood that... Figure 4 This is only a schematic diagram of circuit board 20 and inductor 30; the size, thickness, etc. of circuit board 20 can be changed according to the actual needs of the product. The following is combined with... Figure 4 , Figure 5 or Figure 6 The structure of inductor 30 will be explained.

[0067] like Figure 4 As shown, the inductor 30 includes a winding 34, a carrier plate 31, a support block 32, and a conductive element 33. A circuit board 20 is disposed on one side of the carrier plate 31 along the thickness direction a. At least one end of the winding 34 is disposed between the circuit board 20 and the carrier plate 31. The support block 32 is disposed on the side of the carrier plate 31 facing the circuit board 20, and extends towards the circuit board 20 along the thickness direction a. The conductive element 33 is disposed between the carrier plate 31 and the circuit board 20, with one end of the conductive element 33 fixedly connected to the circuit board 20, the other end of the conductive element 33 fixedly connected to the winding 34, and both ends of the conductive element 33 fixed to the support block 32.

[0068] The support plate 31 is used to support the conductive component 33, the support block 32, and the winding 34, such as Figure 4As shown, in some examples, the conductive element 33, the support block 32, and the winding 34 are all mounted on the carrier plate 31, so that the carrier plate 31 supports the conductive element 33, the support block 32, and the winding 34. In the embodiments of this application, the shape, size, and material of the carrier plate 31 are not limited, as long as the carrier plate 31 can support the conductive element 33, the support block 32, and the winding 34.

[0069] When alternating current passes through winding 34, it generates an alternating magnetic field. This alternating magnetic field can cause electromagnetic interference to other electrical components in the power conversion device. For example, the surface of circuit board 20 is provided with printed lines made of copper. The alternating magnetic field will generate eddy current losses on the copper, causing the copper to heat up. However, the resistance of the conductor increases with the increase of temperature, which leads to increased loss when the current is transmitted through the printed lines formed by the copper on circuit board 20.

[0070] Since the support block 32 is disposed on the side of the carrier plate 31 facing the circuit board 20, and extends toward the circuit board 20 along the thickness direction a of the carrier plate 31, the support block 32 increases the distance between the circuit board 20 and the winding 34. Since the farther away from the magnetic field source (the winding 34 of this application), the weaker the alternating magnetic field is, the electromagnetic interference of the alternating magnetic field generated by the alternating current when passing through the winding 34 on the circuit board 20 is reduced.

[0071] To reduce the impact of the alternating magnetic field generated when AC current passes through winding 34 on other electrical components in the power conversion device, in some examples, the support plate 31 is a metal plate. When the metal plate is in the alternating magnetic field, eddy currents (i.e., eddy currents) are generated in the metal plate due to electromagnetic induction, and these eddy currents generate Joule heat on the metal plate. Since winding 34 and circuit board 20 are located on opposite sides of support plate 31, the alternating magnetic field generated when AC current passes through winding 34 must pass through support plate 31 to reach circuit board 20. A portion of the alternating magnetic field generated when AC current passes through winding 34 generates eddy currents on the metal plate and ultimately converts into Joule heat, thus reducing the electromagnetic interference of the alternating magnetic field generated when current passes through winding 34 on circuit board 20.

[0072] The same principle can be used in this application to reduce electromagnetic interference to other electrical components in the power conversion device caused by the alternating magnetic field generated when AC current passes through winding 34.

[0073] The winding 34 is used to filter high-frequency current. In some examples, to ensure that at least one end of the winding 34 is located between the circuit board 20 and the carrier plate 31, the winding 34 is positioned on the side of the carrier plate 31 facing away from the circuit board 20. The carrier plate 31 has a clearance opening through which the winding 34 extends into the space between the circuit board 20 and the carrier plate 31. In this way, the end of the winding 34 can extend into the space between the circuit board 20 and the carrier plate 31 through the clearance opening, allowing the winding 34 to be connected to the conductive element 33.

[0074] To achieve protection for winding 34, such as Figure 4 As shown, in some examples, the inductor 30 also includes a housing 35, with a winding 34 disposed within the housing 35, and a support plate 31 connected to the housing 35 and covering at least a portion of the opening of the housing 35.

[0075] One end of the conductive element 33 is connected to the circuit board 20, and the other end of the conductive element 33 is connected to the winding 34. That is, the winding 34 is connected to the printed line on the circuit board 20 through the conductive element 33.

[0076] It is understandable that each part in industrial manufacturing has an allowable tolerance range. However, the cumulative tolerances of multiple parts in the assembly direction can lead to a deviation from the intended final fit. In this application, when the conductive component 33 is connected to the circuit board 20, the circuit board 20 exerts a force on the conductive component 33 due to assembly errors and / or processing errors of the power conversion device. Specifically, in the power conversion device of this application, the winding 34, the carrier plate 31, the support block 32, and the conductive component 33 are assembled to form an inductor 30, and then the inductor 30 is connected to the circuit board 20. Therefore, the cumulative tolerances of the winding 34, the carrier plate 31, the support block 32, the conductive component 33, and the circuit board 20 can easily cause the inductor 30 and the circuit board 20 to experience force. If the fit between the conductive component 33 and the circuit board 20 deviates from the design expectation during assembly, that is, if an assembly tolerance occurs between the conductive component 33 and the circuit board 20 during the assembly of the inductor 30 and the circuit board 20, then in order to achieve the connection between the circuit board 20 and the conductive component 33, the conductive component 33 needs to deform to correct the assembly tolerance between the conductive component 33 and the circuit board 20. For the conductive component 33 to deform, it needs to be subjected to a force. When the circuit board 20 and the conductive component 33 are connected, the circuit board 20 can apply a force to the conductive component 33 to cause the conductive component 33 to deform.

[0077] The following are some situations where assembly tolerances occur between conductive component 33 and circuit board 20: In the first scenario, there is a gap between one end of the conductive element 33 and the circuit board 20. When the circuit board 20 and the conductive element 33 are connected, a force is applied to one end of the conductive element 33 away from the support plate 31. The direction of this force can be referenced... Figure 4 Chinese F1.

[0078] In the second scenario, if the length of the conductive element 33 is too long in the thickness direction a of the support plate 31, then when the conductive element 33 is connected to the circuit board 20, the circuit board 20 applies a force towards one end of the conductive element 33, which is directed towards the support plate 31. The direction of this force can be referred to... Figure 4 F2.

[0079] In the third case, the circuit board 20 and the conductive component 33 are misaligned in the thickness direction a perpendicular to the support plate 31. When the conductive component 33 and the circuit board 20 are connected, the circuit board 20 applies a force perpendicular to the thickness direction a of the support plate 31 to one end of the conductive component 33. The direction of this force can be referenced... Figure 4 F3.

[0080] In reality, the first and third situations mentioned above may coexist, or the second and third situations mentioned above may coexist.

[0081] The force applied by the circuit board 20 to the conductive element 33 is transmitted from one end of the conductive element 33 to the other end. However, the other end of the conductive element 33 is connected to the winding 34. After the force applied by the circuit board 20 to the conductive element 33 is transmitted to the other end of the conductive element 33, there is a risk that the connection between the other end of the conductive element 33 and the winding 34 will be damaged by external force.

[0082] When the conductive element 33 is fixed to the support block 32 at any position between its two ends, the force exerted by the circuit board 20 on the conductive element 33 will be at least partially transmitted to the support block 32 after being transmitted to the connection position between the conductive element 33 and the support block 32. The remaining part or no force will be transmitted to the end where the conductive element 33 and the winding 34 are connected. According to the distribution of the force on the conductive element 33, the part of the conductive element 33 between the end connected to the circuit board 20 and the position fixed to the support block 32 will definitely deform, absorbing the force exerted by the circuit board 20 on the conductive element 33. The part of the conductive element 33 between the position connected to the winding 34 and the position fixed to the support block 32 will not produce deformation or will produce a small amount of deformation. Therefore, the influence of the force on the end where the conductive element 33 and the winding 34 are connected is reduced, which reduces the damage caused by the force to the connection strength between the conductive element 33 and the winding 34.

[0083] In order to make the conductive component 33 more easily deformable, such as Figure 4 As shown, in some examples, along the extension path of the conductor 33, the conductor 33 is fixed to the support block 32 near the winding 34.

[0084] The greater the distance between the position where the conductive element 33 is fixed to the support block 32 and the position where the conductive element 33 is connected to the circuit board 20, the longer the lever arm (taking the position where the conductive element 33 is fixed to the support block 32 as the rotation point, the connection point between the conductive element 33 and the circuit board 20 as the force point, and the lever arm as the perpendicular distance from the line of action of the force to the rotation axis). Figure 4Taking the example shown, assuming the direction of the force applied by the circuit board 20 to the end of the conductive component 33 connected to the circuit board 20 is F4, and the position where the conductive component 33 is fixed to the support block 32 is taken as the rotation point, then the lever arm length is r1. Moving the conductive component 33 along its extension path from the position fixed to the support block 32 towards the winding 34, the lever arm length becomes r2. The length of r2 is significantly greater than the length of r1. According to the torque formula T=F×r, the longer the lever arm, the easier it is for the conductive component 33 to deform, thus absorbing the assembly tolerances and processing errors of the power conversion device. Simultaneously, according to the principle that action equals reaction, the reaction force applied by the conductive component 33 to the circuit board 20 is also smaller, and the structure of the circuit board 20 is less affected by the reaction force. Here, T is the torque, F is the force, and r is the lever arm length.

[0085] It is understood that the conductive element 33 has the ability to deform after being subjected to external force from the circuit board 20. In this embodiment, the type of conductive element 33 is not limited. Two examples of conductive element 33 are given below.

[0086] In the first example, the conductive element 33 is a busbar. As a solid conductor, the busbar has a large cross-sectional area, can stably carry and efficiently transmit large currents of hundreds to thousands of amperes, and has low power loss. It is suitable for the transmission of large currents after converting DC to AC in power conversion devices.

[0087] In the second example, the conductive element 33 is a conductive strip. The conductive strip is woven from multiple layers of copper foil or multiple strands of copper wire, which means that the conductive strip has excellent flexibility. Its flexible structure can effectively compensate for the processing error or assembly error of the power conversion device, so that the circuit board 20 cannot apply force to it. It can also effectively absorb and compensate for the vibration, displacement and thermal expansion and contraction generated by the operation of the equipment, and prevent the connection between the conductive strip and the winding 34 from being damaged due to force.

[0088] To fix the conductive element 33 to the support block 32, the embodiments of this application provide the following three methods for fixing the conductive element 33 to the support block 32: like Figure 4 As shown, in the first method, a through hole 331 is provided between the two ends of the conductive element 33 along the extension path of the conductive element 33; a first fastener 40A is provided on the support block 32; the power conversion device also includes a first fixing element 40B, which passes through the through hole 331 and is fixedly connected to the first fastener 40A.

[0089] A first fastener 40A is provided on the support block 32, and a first fixing member 40B passes through the through hole 331 provided on the conductive member 33 and is connected to the first fastener 40A. The first fixing member 40B can firmly press the conductive member 33 onto the support block 32. The force applied by the circuit board 20 to the conductive member 33 is limited between the end of the conductive member 33 connected to the circuit board 20 and the position fixed to the support block 32. The part of the conductive member 33 between the end connected to the circuit board 20 and the position fixed to the support block 32 deforms and completely absorbs the force applied by the circuit board 20 to the conductive member 33. No force is transmitted to the part of the conductive member 33 between the winding 34 and the position fixed to the support block 32. Therefore, the part of the conductive member 33 between the winding 34 and the position fixed to the support block 32 does not deform at all. The connection relationship between the conductive member 33 and the winding 34 is not affected by the force applied by the elastic circuit board 20 to the conductive member 33, thus protecting the connection strength between the conductive member 33 and the winding 34.

[0090] In this embodiment, the first fastener 40A and the first fixing member 40B are not limited. For example, in some examples, the first fastener 40A may be a nut and the first fixing member 40B may be a stud.

[0091] To prevent the first fastener 40A from interfering with the extension path of the conductive element 33 on the surface of the support block 32, in some examples, a first groove is provided on the support block 32, and the first fastener 40A is fixed in the first groove, that is, the first fastener 40A is hidden in the support block 32, so the first fastener 40A will not interfere with the extension path of the conductive element 33 on the surface of the support block 32.

[0092] Figure 5 Another connection diagram of inductor 30 and circuit board 20 provided in an embodiment of this application; Figure 6 For the support block 32, conductive element 33 and buckle 322 along Figure 5 A sectional view of section AA in the middle.

[0093] like Figure 5 and Figure 6 As shown, in the second method, the support block 32 is provided with a buckle 322, and along the extension path of the conductive member 33, the two ends of the conductive member 33 are engaged with the buckle 322 at any position.

[0094] A latch 322 is provided on the support block 32, and the conductive element 33 is latched to the latch 322 at any position between its two ends. The force exerted by the circuit board 20 on the conductive element 33 is at least partially limited to the portion between the end of the conductive element 33 connected to the circuit board 20 and the position fixed to the support block 32. Therefore, the portion of the conductive element 33 between the connection to the winding 34 and the position fixed to the support block 32 bears part or no force exerted by the circuit board 20 on the conductive element 33, reducing or completely eliminating the damage to the connection strength between the conductive element 33 and the winding 34 caused by this force. Furthermore, by fixing the conductive element 33 with the latch 322, the structure of the conductive element 33 does not need to be changed. Most importantly, no holes are needed on the conductive element 33, so the effective cross-sectional area of ​​the conductive element 33 is not reduced, ensuring the current transmission efficiency of the conductive element 33.

[0095] like Figure 5 and Figure 6 As shown, in some examples, the buckle 322 includes two elastic arms 3221 arranged opposite each other. Along the width direction of the conductive member 33, the two elastic arms 3221 are arranged on opposite sides of the conductive member 33. A locking block 3222 is protruded on the side of the elastic arm 3221 facing the other elastic arm 3221. That is, the elastic arm 3221 and the buckle 322 arranged on itself form an L-shape. After the conductive member 33 is between the two elastic arms 3221, the locking block 3222 can prevent the conductive member 33 from coming out between the two elastic arms 3221.

[0096] Figure 7 This is a schematic diagram showing the connection between an inductor 30 and a circuit board 20, as provided in an embodiment of this application.

[0097] like Figure 7 As shown, in the third method, a positioning hole 337 is provided between the two ends of the conductive element 33 along the extension path of the conductive element 33; a positioning pin 321 is provided on the support block 32, and the positioning pin 321 is inserted into the positioning hole 337.

[0098] A positioning pin 321 is provided on the support block 32. A positioning hole 337, which mates with the positioning pin 321, is provided between the two ends of the conductive component 33. After the positioning pin 321 is inserted into the positioning hole 337, the conductive component 33 is fixed to the support block 32. The force exerted by the circuit board 20 on the conductive component 33 is limited to the portion of the conductive component 33 connecting to the circuit board 20 and the positioning hole 337. The portion of the conductive component 33 connecting the winding 34 and the positioning hole 337 bears part of the force exerted by the circuit board 20 on the conductive component 33, reducing the damage to the connection strength between the conductive component 33 and the winding 34 caused by this force. Furthermore, when assembling the conductive component 33 to the support block 32, it is only necessary to insert the positioning pin 321 into the positioning hole 337 to fix the conductive component 33 to the support block 32, making the assembly of the conductive component 33 very convenient.

[0099] To prevent the conductive element 33 from detaching from the positioning pin 321, in some examples, the positioning pin 321 includes a rod and a head connected in sequence, with the equivalent diameter of the head being larger than the equivalent diameter of the rod. That is, the positioning pin 321 has a mushroom-shaped end at the end furthest from the support block 32, which prevents the conductive element 33 from detaching from the positioning pin 321. In other examples, the sidewall of the positioning pin 321 has an annular groove, and the power conversion device also includes a retaining ring 50 installed within the annular groove, which also prevents the conductive element 33 from detaching from the positioning pin 321.

[0100] Figure 8A This is a schematic diagram of the structure of a conductive element 33 provided in an embodiment of this application. Figure 8B This is a schematic diagram of another conductive element 33 provided in an embodiment of this application. Figure 8A and Figure 8B The extension path of the second segment 334 of the intermediate conductive component 33 is different.

[0101] To facilitate the connection between the conductive component 33 and the circuit board 20, such as Figure 8A or Figure 8B As shown, in some examples, the conductive element 33 includes a first segment 333 connected to the circuit board 20. The first segment 333 extends in a direction parallel to the circuit board 20 and is disposed between the support block 32 and the circuit board 20.

[0102] The first segment 333 is used to connect with the circuit board 20. In some examples, the first segment 333 is set to extend perpendicularly to the thickness direction a of the carrier plate 31. Then, along the thickness direction a of the carrier plate 31, the first segment 333 and the circuit board 20 have a larger overlapping area. In this way, the conductive element 33 has a larger area to connect with the circuit board 20, which facilitates the connection between the conductive element 33 and the circuit board 20.

[0103] To facilitate the connection between the conductive element 33 and the winding 34, such as Figure 8A or Figure 8B As shown, in some examples, the conductive element 33 includes a third segment 335 connected to the winding 34, and the third segment 335 extends toward the winding 34 along the thickness direction a of the carrier plate 31.

[0104] The third segment 335 has another end, and the third segment 335 is connected to the winding 34. Along the thickness direction a of the support plate 31, after the third segment 335 extends toward the winding 34, the third segment 335 can be connected to the end of the winding 34 located between the circuit board 20 and the support plate 31, which facilitates the connection between the conductive component 33 and the winding 34.

[0105] In order to fix the conductive element 33 to the support block 32, such as Figure 8A or Figure 8BAs shown, in some examples, the conductive element 33 further includes a second segment 334, which is fixed to the support block 32 (see reference). Figure 4 , Figure 5 or Figure 7 ).

[0106] In this embodiment, the extension path of the second segment 334 is not limited; the second segment 334 can be extended along any path. For example, as Figure 8A As shown, the second segment 334 extends in the thickness direction a of the support plate 31. For example, as... Figure 8B As shown, the second segment 334 can be set at an angle to the thickness direction a of the support plate 31. It is understood that the extension path of the second segment 334 is not limited to a straight line; the extension path of the second segment 334 can be arc-shaped or wavy, etc.

[0107] In the embodiments of this application, the first segment 333, the second segment 334, and the third segment 335 are connected sequentially.

[0108] Figure 9 , Figure 10 and Figure 11 These are all schematic diagrams showing the connection between the inductor 30 and the circuit board 20 provided in the embodiments of this application. Figure 9 , Figure 10 and Figure 11 The conductive element 33 is fixed to the support block 32 at different positions. (The following is a continuation of the previous sentence.) Figure 9 , Figure 10 and Figure 11 The conductive element 33 is fixed to the position of the support block 32.

[0109] like Figure 9 , Figure 10 or Figure 11 As shown, in some examples, along the thickness direction a of the support plate 31 and the direction parallel to the circuit board 20, the first segment 333 can move relative to the support block 32. The first segment 333 is not fixed and can move freely. Therefore, the first segment 333 can move relative to the circuit board 20 to adjust the relative position between the first segment 333 and the circuit board 20, so that the first segment 333 can deform to compensate for the assembly tolerance between the first segment 333 and the circuit board 20.

[0110] The first segment 333 not only needs to be connected to the circuit board 20, but also needs to move relative to the support block 32, such as... Figure 9 , Figure 10 or Figure 11As shown, in some examples, the power conversion device includes a second fastener 70B and a second fastener 70A. The second fastener 70B passes through the circuit board 20 and the first segment 333 and is connected to the second fastener 70A. In this way, the circuit board 20 and the first segment 333 are fixedly connected through the cooperation of the second fastener 70B and the second fastener 70A.

[0111] In this application, the second fastener 70B can be a bolt, and the second fastener 70A can be a nut. Bolts and nuts are technically mature and have reliable connections.

[0112] To reduce the impact of the second fastener 70A on the support block 32, such as Figure 9 , Figure 10 or Figure 11 As shown, in some examples, the support block 32 has a second groove on the side facing the circuit board 20, and a second fastener 70A is provided in the second groove, so that the second fastener 70A is hidden in the second groove.

[0113] When connecting the first segment 333 and the circuit board 20, the first segment 333 and the circuit board 20 need to be aligned. Therefore, the first segment 333 will move in the thickness direction a of the support plate 31 and in the plane parallel to the circuit board 20. The corresponding second fastener 70A also needs to be aligned with the first segment 333 and the circuit board 20. Therefore, in some examples, the second fastener 70A can move in the second groove along the depth direction of the second groove and in the direction parallel to the circuit board 20; and the sidewall of the second groove can restrict the second fastener 70A from rotating in the second groove.

[0114] Since the second fastener 70A can move along the depth direction of the second groove within the second groove, the second fastener 70A can move with the first segment 333 towards or away from the circuit board 20 as the first segment 333 moves. Because the second fastener 70A can move within the second groove on a plane parallel to the circuit board 20, when the first segment 333 and the circuit board 20 are not connected, and the first segment 333 needs to be aligned with the circuit board 20 and thus undergoes displacement in the direction parallel to the circuit board 20, the second fastener 70A can also move within the second groove on a plane parallel to the circuit board 20, allowing the second fixing member 70B to align with the second fastener 70A after passing through the circuit board 20 and the first segment 333. Furthermore, the sidewall of the second groove can restrict the rotation of the second fastener 70A within the second groove, preventing the second fastener 70A from rotating synchronously with the second fixing member 70B when the second fixing member 70B is connected.

[0115] To further reduce the risk of damage to the connection between the conductor 33 and the winding 34 caused by the force applied by the circuit board 20 to the conductor 33, in some examples, the second segment 334 is provided with a bend.

[0116] After the circuit board 20 applies a force to the conductive component 33, stress concentration will occur at the bending position of the second segment 334. When the conductive component 33 deforms, the deformation of the conductive component 33 is mainly concentrated at the bending position. Thus, the deformation of the conductive component 33 mainly occurs in the second segment 334 of the conductive component 33, minimizing the deformation of the first segment 333 and the third segment 335. The deformation of the conductive component 33 between the part connecting the winding 34 and the part fixed to the support block 32 is reduced, further reducing the damage of the force to the connection strength between the conductive component 33 and the winding 34.

[0117] The following embodiments of this application provide two structures that can be bent: like Figure 9 , Figure 10 or Figure 11 As shown, in the first structure, the second segment 334 includes a first sub-segment 3341 and a second sub-segment 3342 connected in sequence. The end of the first sub-segment 3341 away from the second sub-segment 3342 is connected to the first segment 333, and the first sub-segment 3341 extends along the thickness direction a of the supporting plate 31. The end of the second sub-segment 3342 away from the first sub-segment 3341 is connected to the third segment 335, and the second sub-segment 3342 extends perpendicular to the thickness direction a of the supporting plate 31. Thus, the first sub-segment 3341 and the second sub-segment 3342 extend in different directions, forming a bend between the first sub-segment 3341 and the second sub-segment 3342. When the conductive element 33 is subjected to force, the stress is mainly concentrated in the bend formed between the first sub-segment 3341 and the second sub-segment 3342.

[0118] After the circuit board 20 applies a force along the thickness direction of the support plate 31 to the conductive element 33, the first segment 3341 extends along the thickness direction a of the support plate 31. When the force applied by the circuit board 20 to the end of the conductive element 33 connected to the circuit board 20 has a component perpendicular to the thickness direction a of the support plate 31, the first segment 3341 begins to deform around itself and the connection point of the second segment 3342. The greater the distance between the first segment 3341 and the second segment 3342, the greater the deformation, in order to compensate for the processing error or assembly error of the power conversion device in the thickness direction a perpendicular to the support plate 31. For example, the electrical... The connection hole of the circuit board 20 and the end of the conductive element 33 near the circuit board 20 are not aligned; when the force applied by the circuit board 20 to the end of the conductive element 33 connected to the circuit board 20 has a component force in the thickness direction a parallel to the support plate 31, the second segment 3342 begins to deform around the connection between itself and the first segment 3341, and the deformation is greater the farther the second segment 3342 is from the first segment 3341, in order to compensate for the processing error or assembly error of the power conversion device in the thickness direction a parallel to the support plate 31. For example, there is a gap between the circuit board 20 and the end of the conductive element 33 near the circuit board 20.

[0119] It can be understood that the first segment 333 and the first sub-segment 3341 also form a bend, and the second sub-segment 3342 and the third segment 335 also form a bend. However, after the conductive element 33 is fixed to the support block 32, the third segment 335 does not deform. The deformation and effect between the first segment 333 and the first sub-segment 3341 can be referred to the first sub-segment 3341 and the second sub-segment 3342, which will not be repeated here.

[0120] In conjunction with the second segment 334 being fixed to the support block 32, in some examples, at least one of the first sub-segment 3341 and the second sub-segment 3342 is fixed to the support block 32.

[0121] like Figure 9 As shown, the first segment 3341 of the conductive element 33 is fixed to the support block 32.

[0122] like Figure 10 As shown, the second segment 3342 of the conductive element 33 is fixed to the support block 32.

[0123] like Figure 11 As shown, the first segment 3341 and the second segment 3342 of the conductive element 33 are both fixed to the support block 32.

[0124] In conjunction with the aforementioned extension path along the conductive element 33, the conductive element 33 is fixed to the support block 32 at a position near the winding 34. Preferably, the second segment 3342 of the conductive element 33 is fixed to the support block 32.

[0125] To enhance the support of the support block 32 for the conductive component 33, such as Figure 9 , Figure 10 or Figure 11 As shown, in some examples, the side of the support block 32 facing the circuit board 20 includes a first platform 323 and a second platform 324, which are connected by a first side 325; the first platform 323 is parallel to the first segment 333, the first side 325 is parallel to the first sub-segment 3341, and the second platform 324 is parallel to the second sub-segment 3342; along the thickness direction a of the bearing plate 31, the first segment 333 is disposed between the first platform 323 and the circuit board 20; the first sub-segment 3341 is fixedly connected to the first side 325, and / or the second sub-segment 3342 is fixedly connected to the second platform 324.

[0126] The first segment 333 is positioned between the first platform 323 and the circuit board 20. The first segment 333 is close to the circuit board 20, facilitating the connection between the first segment 333 and the circuit board 20. The first sub-segment 3341 is fixed to the first side 325, and / or the second sub-segment 3342 is fixed to the second platform 324, both of which can fix the second segment 334 to the support block 32. At the same time, the first sub-segment 3341 is parallel to the first side 325, and the second sub-segment 3342 is parallel to the second side. The shape of the support block 32 corresponds to the shape of the conductive element 33, so that the conductive element 33 can fit against the surface of the support block 32, and the support block 32 can better support the conductive element 33.

[0127] Figure 12 This is a schematic diagram of the structure of various conductive elements 33 provided in the embodiments of this application.

[0128] like Figure 12 As shown, in the second structure, the second segment 334 is provided with an arc-shaped segment 336, and the second segment 334 is fixed to the support block 32 at a position other than the arc-shaped segment 336.

[0129] The structure of the arc segment 336 is smoother. When the conductive element 33 is subjected to force, the stress is distributed more dispersedly on the entire arc segment 336, rather than concentrated at a certain point. In this way, the arc segment 336 can not only concentrate the deformation of the conductive element 33 on itself, but also avoid stress concentration that could cause the arc segment 336 to be damaged due to excessive stress.

[0130] To prevent the curved segment 336 and the support block 32 from interfering with each other, such as Figure 8B As shown, in some examples, the arc segment 336 protrudes away from the support block 32, so that the conductive element 33 and the support block 32 do not interfere with each other even after the arc segment 336 is set.

[0131] Figure 13 This is a schematic diagram of another conductive element 33 provided in an embodiment of this application. (See attached diagram.) Figure 13As shown, in some examples, the conductive element 33 includes multiple arc segments 336, each of which is disposed in the second segment 334. The multiple arc segments 336 can distribute the deformation of the conductive element 33 and reduce the stress concentration of each arc segment 336.

[0132] To reduce the cost and weight of the power conversion device, in some examples, the winding 34 is made of aluminum. Using aluminum for the winding 34 reduces its cost. Furthermore, the lighter weight of the aluminum inductor 30 further reduces the weight of the power conversion device.

[0133] In some examples, the conductive element 33 is made of copper. The main function of the conductive element 33 is to transmit the filtered current from the winding 34 to the circuit board 20. When the conductive element 33 is made of copper, it has excellent conductivity. Therefore, the copper conductive element 33 can transmit DC power from the circuit board 20 to the winding 34 more quickly, and can also transmit AC power output from the winding 34 to the circuit board 20 more quickly.

[0134] Although the conductive element 33 and the winding 34 are made of different materials, resulting in poor connection strength after direct welding, in this application, the force applied by the circuit board 20 to the conductive element 33 cannot be transmitted to either the conductive element 33 or the winding 34. Even though the winding 34 and the conductive element 33 are made of different materials, the connection strength between them after welding is not affected by external forces and can still be guaranteed. Therefore, in order to reduce the cost of the power conversion device, such as... Figure 9 , Figure 10 or Figure 11 As shown, in some examples, the conductive element 33 and the winding 34 are made of different materials, and the other end of the conductive element 33 is directly connected to the winding 34.

[0135] Figure 14 This is a schematic diagram showing another connection between the inductor 30 and the circuit board 20 provided in an embodiment of this application. Figure 15 This is a schematic diagram of a conductive element 33 connected to a winding 34 via an adapter 60, as provided in an embodiment of this application. Figure 16 This is a schematic diagram of another conductive element 33 connected to the winding 34 via an adapter 60, as provided in an embodiment of this application.

[0136] like Figure 14 and Figure 15 As shown, or as Figure 14 and Figure 16As shown, in some examples, the power conversion device further includes an adapter 60, which includes an integrally formed first connecting portion 61 and a second connecting portion 62. The first connecting portion 61 is connected to the winding 34, and the first connecting portion 61 and the winding 34 are made of the same material. The second connecting portion 62 is connected to the conductive element 33, and the second connecting portion 62 and the conductive element 33 are made of the same material.

[0137] The winding 34 and the conductive element 33 are usually connected by welding. When the winding 34 and the conductive element 33 are made of different materials, the connection strength after direct welding is very poor. The first connecting part 61 of the adapter 60 is made of the same material as the winding 34, so the connection strength after welding the winding 34 and the first connecting part 61 is stronger. The second connecting part 62 of the adapter 60 is made of the same material as the conductive element 33, so the connection strength after welding the conductive element 33 and the second connecting part 62 is stronger. Since the adapter 60 is integrally set, the strength of the adapter 60 is higher than the strength after welding two different materials, which improves the connection strength between the ends of the conductive element 33 and the winding 34.

[0138] The type of adapter 60 is not limited in this embodiment of the application, such as Figure 15 As shown, in some examples, adapter 60 is a connection terminal; such as Figure 16 As shown, in some other examples, adapter 60 is an adapter bar.

[0139] Figure 17 This is a schematic diagram showing the connection between an inductor 30 and a circuit board 20 as provided in the embodiment of the application.

[0140] The support block 32 is used to support the conductive element 33 and fix the conductive element 33. In some examples, the shape of the support block 32 is not limited in this embodiment, as long as the support block 32 can fix the conductive element 33. In some examples, the conductive element 33 extends along the surface of the support block 32, or in other words, the surface of the support block 32 is arranged corresponding to the extension path of the conductive element 33, for example, as shown in the example. Figure 17 As shown, when the conductive component 33 includes a first segment 333, a first sub-segment 3341, a second sub-segment 3342 and a third segment 335, a stepped surface is provided on the support block 32 corresponding to the conductive component 33.

[0141] In some examples, the inductor 30 includes multiple windings 34, multiple conductive elements 33, and multiple support blocks 32. One end of each conductive element 33 is connected to the circuit board 20, and the other end of each conductive element 33 is connected to a corresponding winding 34. The two support blocks 32 corresponding to two adjacent windings 34 are integrally formed. After the two support blocks 32 corresponding to two windings 34 are integrally formed, one support block 32 supports two conductive busbars at the same time, simplifying the structure of the inductor 30.

[0142] It is understandable that winding 34 has two ends, such as Figure 17 As shown, both ends of the winding 34 can be connected to the conductive element 33 and the circuit board 20 in this application.

[0143] In the description of this specification, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0144] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any modifications or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A power conversion device, characterized in that, The power conversion device includes a housing, an inductor, and a circuit board, with the circuit board disposed inside the housing; wherein the inductor includes windings, a carrier plate, a support block, and conductive components; Along the thickness direction of the support plate, the circuit board is disposed on one side of the support plate; At least one end of the winding is disposed between the circuit board and the carrier plate; The support block is disposed on the side of the carrier plate facing the circuit board, and extends toward the circuit board along the thickness direction of the carrier plate; The conductive element is disposed between the carrier plate and the circuit board. One end of the conductive element is fixedly connected to the circuit board, and the other end of the conductive element is fixedly connected to the winding. The two ends of the conductive element are fixed to the support block.

2. The power conversion device according to claim 1, characterized in that, Along the extension path of the conductive element, a through hole is provided between the two ends of the conductive element; The support block is provided with a first fastener; The power conversion device further includes a first fixing member, which passes through the through hole and is fixedly connected to the first fastener.

3. The power conversion device according to claim 1, characterized in that, The support block is provided with a buckle, and the two ends of the conductive element are engaged with the buckle along the extension path of the conductive element.

4. The power conversion device according to claim 1, characterized in that, A positioning hole is provided between the two ends of the conductive element along the extension path of the conductive element. The support block is provided with a positioning pin, which is inserted into the positioning hole.

5. The power conversion device according to any one of claims 1-4, characterized in that, The conductive component includes a first segment, a second segment, and a third segment connected in sequence; The first segment is connected to the circuit board, and the first segment extends in a direction parallel to the circuit board and is disposed between the support block and the circuit board; The second segment is fixed to the support block; The third segment is connected to the winding and extends toward the winding along the thickness direction of the bearing plate.

6. The power conversion device according to claim 5, characterized in that, Along the thickness direction of the bearing plate, the support block has a first groove on the side facing the circuit board. A second fastener is disposed in the first groove. Along the depth direction of the first groove, the second fastener can move within the first groove. The sidewall of the first groove can restrict the first fastener from rotating within the first groove. The power conversion device further includes a second fastener, which passes through the circuit board and the first segment and is connected to the second fastener.

7. The power conversion device according to claim 5, characterized in that, The second segment has a bend, and the second segment is fixed to the support block at a position outside the bend.

8. The power conversion device according to claim 7, characterized in that, The second segment includes a first sub-segment and a second sub-segment connected in sequence. The end of the first sub-segment away from the second sub-segment is connected to the first segment, and the first sub-segment extends along the thickness direction of the support plate. The end of the second sub-segment away from the first segment is connected to the third segment, and the second sub-segment extends perpendicular to the thickness direction of the support plate.

9. The power conversion device according to claim 8, characterized in that, The side of the support block facing the circuit board includes a first platform and a second platform, which are connected by a first side; the first platform is parallel to the first segment, the first side is parallel to the first sub-segment, and the second platform is parallel to the second sub-segment; Along the thickness direction of the support plate, the first segment is disposed between the first platform and the circuit board and is fixed to the circuit board; The first sub-segment is fixedly connected to the first side, and / or the second sub-segment is fixedly connected to the second platform.

10. The power conversion device according to claim 7, characterized in that, The second segment is provided with an arc-shaped section, which protrudes away from the support block, and the second segment is fixed to the support block at a position outside the arc-shaped section.

11. The power conversion device according to any one of claims 1-10, characterized in that, The power conversion device further includes an adapter, and the other end of the conductive element is fixedly connected to the winding through the adapter; the adapter includes an integrally formed first connecting part and a second connecting part, the first connecting part is fixedly connected to the winding, and the first connecting part and the winding are made of the same material; the second connecting part is fixedly connected to the conductive element, and the second connecting part and the conductive element are made of the same material.

12. The power conversion device according to any one of claims 1-10, characterized in that, The conductive element and the winding are made of different materials, and the other end of the conductive element is directly connected to the winding.

13. The power conversion device according to any one of claims 1-12, characterized in that, The conductive component is made of copper, and the winding is made of aluminum.

14. The power conversion device according to any one of claims 1-13, characterized in that, The conductive component is a conductive busbar or a conductive strip.

15. The power conversion device according to any one of claims 1-14, characterized in that, The inductor includes multiple windings, multiple conductive elements, and multiple support blocks; one end of each of the multiple conductive elements is connected to the circuit board, and the other end of each of the multiple conductive elements is connected to the corresponding winding. The two support blocks corresponding to two adjacent windings are integrally formed.

16. An inductor, characterized in that, The inductor, used in a power conversion device with a circuit board, comprises windings, a carrier plate, a support block, and conductive components; wherein, Along the thickness direction of the support plate, the circuit board is disposed on one side of the support plate; At least one end of the winding is disposed between the circuit board and the carrier plate; The support block is disposed on the side of the carrier plate facing the circuit board, and extends toward the circuit board along the thickness direction of the carrier plate; The conductive element is disposed between the carrier plate and the circuit board. One end of the conductive element is connected to the circuit board, and the other end of the conductive element is connected to the winding. The conductive element is fixed to the support block between its two ends.

Images