Power conversion device

Abstract

A power conversion device includes a housing, a circuit board, and an AC terminal. The shell comprises a bottom plate and a cover plate. The bottom plate and the cover plate are oppositely arranged in a spaced mode in the first direction. The circuit board and the bottom plate are oppositely arranged in the first direction and located between the cover plate and the bottom plate. The AC terminal includes a substrate and a plurality of electrical connectors. The substrate is arranged between the bottom plate and the circuit board. The plurality of electric connecting pieces penetrate through the substrate and are fixedly connected with the substrate, one end of each electric connecting piece is fixedly and electrically connected with the circuit board, and the other end of each electric connecting piece is located outside the shell and used for being connected with a power grid or a load. No cable is arranged between the AC terminal and the circuit board, so that the space occupancy rate in the shell is reduced, and the size limitation of the shell in the first direction is reduced; the other end of the electric connecting piece can extend out of the shell from the bottom plate, so that the distance between the bottom plate and the circuit board in the first direction is effectively reduced, the local size of the shell in the first direction is further reduced, and the overall power density of the power conversion device is improved.

Description

Technical Field

[0001] The present application relates to the field of photovoltaic energy technology, and in particular to a power conversion device. Background Art

[0002] With the development of power electronics technology, high density and minimalism are the current development trends of inverters. The output current terminals in the inverter are commonly used devices for electrical connection between the inverter and other electronic and electrical equipment (such as power grids or loads). The output current terminals are usually connected to the circuit boards inside the inverter through cables, and the large size of the shell of the current terminals makes it impossible to further reduce the cavity of the whole machine, which greatly limits the improvement of power density. Utility Model Content

[0003] The technical problem to be solved by the embodiments of the present application is to provide a power conversion device that is beneficial to improving power density.

[0004] The present application provides a power conversion device, which includes a housing, a circuit board and an AC terminal, wherein the housing includes a base plate and a cover plate. The base plate and the cover plate are arranged relative to each other along a first direction. The circuit board and the base plate are arranged relative to each other along a first direction and are located between the cover plate and the base plate. The AC terminal includes a substrate and a plurality of electrical connectors. The substrate is arranged between the base plate and the circuit board. The plurality of electrical connectors penetrate the substrate and are connected and fixed to the substrate, one end of the electrical connector is connected and fixed to the circuit board and is electrically connected, the other end of the electrical connector is located outside the housing, and the other end of the electrical connector is used to connect to a power grid or a load.

[0005] The output current-carrying terminal in the inverter is a common device for realizing electrical connection between the inverter and other electronic and electrical equipment (such as the power grid or load). The output current-carrying terminal is usually connected to the circuit board inside the inverter through a cable, and the large size of the shell of the current-carrying terminal makes it impossible to further reduce the cavity of the whole machine, which greatly limits the improvement of power density.

[0006] In the present application, one end of the electrical connector extends to the circuit board and is connected and fixed to the circuit board by welding to achieve electrical connection. There is no cable installation between the AC terminal and the circuit board, which is conducive to reducing the space occupancy rate in the housing and reducing the size restriction of the housing along the first direction; the substrate is installed between the bottom plate and the circuit board, and the other end of the electrical connector passes through the substrate and can extend from the bottom plate to the outside of the housing, which can effectively reduce the distance between the bottom plate and the circuit board along the first direction, which is conducive to further reducing the local size of the housing along the first direction, thereby facilitating the improvement of the overall power density of the power conversion device. In addition, the AC terminal and the circuit board do not require cable transfer, which simplifies the manufacturing process and can effectively reduce the connection power consumption, which is conducive to reducing the electromagnetic compatibility (EMC) risk of the power conversion device.

[0007] In a possible implementation, the bottom plate is provided with a through hole, and the through hole is used to allow the other ends of the plurality of electrical connectors to extend out of the housing. The power conversion device further includes a first seal, which is provided between the substrate and the bottom plate, and the first seal is respectively attached to the substrate and the bottom plate on two opposite sides along a first direction, and the first seal surrounds the plurality of electrical connectors.

[0008] The number of first seals can be set to one, and multiple electrical connectors can be waterproofly sealed by one first seal, without the need to seal each electrical connector separately, effectively reducing the impact of the manufacturing tolerance of different seals on the sealing effect, which is conducive to improving the waterproof sealing performance of the first seal for the power conversion device. Specifically, the first seal can be squeezed to make the two opposite sides of the first seal along the first direction tightly fit on the substrate and the bottom plate, which is conducive to improving the airtightness of the installation interface between the substrate and the bottom plate.

[0009] In a possible implementation manner, at least one of the bottom plate and the base plate is provided with a groove, and the groove is used to install the first sealing member.

[0010] With such arrangement, the groove positions and limits the installation of the first sealing member, thereby reducing displacement of the first sealing member and affecting the waterproof sealing performance.

[0011] In a possible implementation, the AC terminal further includes a plurality of mounting portions corresponding to the plurality of electrical connectors. The plurality of mounting portions are arranged in an array, the plurality of mounting portions are convexly disposed on a side of the substrate facing the bottom plate and at least partially located outside the housing, and each mounting portion is embedded with an electrical connector.

[0012] In this way, the mounting part insulates and protects the portion of the electrical connector extending outside the housing. The electrical connector is embedded in the mounting part. Specifically, the mounting part and the electrical connector can be molded by insert injection molding, and the molded electrical connector is placed in a mold of the injection molding mounting part, and the injection molding material of the mounting part is poured into the mold, so that the mounting part and the electrical connector are connected as a whole, thereby improving the airtightness of the electrical connector and the mounting part.

[0013] In a possible implementation, the AC terminal further includes a plurality of first baffles. The first baffles are disposed between two adjacent mounting portions, and the size of the first baffles along the first direction is greater than the size of the electrical connector.

[0014] The first baffle performs insulation treatment on two adjacent electrical connectors, which can effectively increase the creepage distance between the two adjacent electrical connectors along the first direction and effectively reduce the risk of creepage.

[0015] In a possible implementation, the power conversion device further includes a plurality of distribution terminals corresponding to the plurality of electrical connectors. The plurality of distribution terminals all extend along a second direction, and the second direction is perpendicular to the first direction. One end of the distribution terminal is connected and fixed to the electrical connector, and the other end of the distribution terminal is located on one side of the mounting portion along the second direction and is used to connect to a power grid or a load.

[0016] The current direction from the circuit board to the electrical connector is defined as the drainage direction, and the current direction from the electrical connector to the power distribution terminal is defined as the outflow direction. In this possible implementation, the drainage direction is perpendicular to the outflow direction, which can effectively reduce the size of the AC terminal extending out of the housing along the first direction, thereby facilitating the reduction of the size of the power conversion device along the first direction, and facilitating the improvement of the power density of the power conversion device.

[0017] In a possible implementation manner, along the second direction, a size of the first baffle is larger than a size of the electrical connector.

[0018] With such arrangement, the first baffle can increase the creepage distance between two adjacent electrical connectors along the second direction, which is helpful to reduce the risk of creepage.

[0019] In a possible implementation, the AC terminal further includes a second baffle, which is disposed on the other side of the plurality of mounting portions along the second direction and connected to the plurality of first baffles. Along the first direction, the size of the second baffle is larger than that of the electrical connector.

[0020] The second baffle is arranged opposite to the other end of the power distribution terminal in the second direction, and the second baffle effectively blocks the creepage phenomenon of two adjacent electrical connectors on the other side of the multiple mounting parts along the second direction, further reducing the risk of creepage. The second baffle is connected to multiple first baffles, and the size of the first baffle along the second direction can be appropriately reduced, reducing the space occupied by the AC terminal in the housing, which is conducive to improving the power density of the power conversion device.

[0021] In a possible implementation, the power conversion device further includes a waterproof cover, which is fixed to a side of the bottom plate away from the circuit board and covers a through hole, and accommodates a plurality of mounting portions and a plurality of power distribution terminals.

[0022] A waterproof cover is added outside the shell to provide waterproof protection for the part of the AC terminal outside the shell, thereby improving the waterproof performance of the power conversion device.

[0023] In a possible implementation, the waterproof cover includes a sealing surface, which is parallel to a side of the bottom plate facing away from the circuit board. The power conversion device also includes a second sealing member, which surrounds a through hole, and the second sealing member is in contact with the sealing surface along a first direction, and the second sealing member is in contact with a side of the bottom plate facing away from the circuit board along the first direction.

[0024] The sealing surface is arranged to fit with the second sealing member, which effectively improves the sealing performance between the waterproof cover and the base plate. When the waterproof cover is fixed on the base plate, the force applied to the waterproof cover can tightly press the second sealing member between the sealing surface and the base plate, thereby strengthening the waterproof sealing protection of the AC terminal.

[0025] In a possible implementation, the waterproof cover further includes an opening, and the opening is used to pass the other end of the power distribution terminal.

[0026] The opening of the waterproof cover can be used to extend the other end of the distribution terminal out of the waterproof cover to connect to the power grid or load. The opening can be sealed and waterproofed to strengthen the waterproof protection of the AC terminal, which is beneficial to improving the waterproof performance of the power conversion device.

[0027] In a possible implementation, the AC terminal further includes a positioning post, which is protruding from a side of the substrate facing the circuit board, and the circuit board is provided with a positioning hole, which is used to cooperate with the positioning post.

[0028] With such an arrangement, accurate positioning between the electrical connector and the circuit board is achieved through the positioning posts, which is beneficial to improving the assembly efficiency of the electrical connector and the circuit board.

[0029] In a possible implementation, the AC terminal further includes a support portion, which is protruding from a side of the substrate facing the circuit board and is connected to the circuit board.

[0030] The support portion controls the welding height between the electrical connector and the circuit board, which can effectively absorb the connection tolerance between different electrical connectors and the circuit board, and is beneficial to reducing the stress of the soldering point. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the background technology, the drawings required for use in the embodiments of the present application or the background technology will be described below.

[0032] Figure 1 A schematic diagram of the networking of a photovoltaic storage system in a large ground power station or industrial and commercial application scenario provided by an embodiment of the present application;

[0033] Figure 2 A schematic diagram of the structure of a power conversion device provided in one embodiment of the present application;

[0034] Figure 3 for Figure 2 A schematic diagram of a partially exploded structure of a power conversion device shown;

[0035] Figure 4 A schematic structural diagram of an AC terminal from one perspective provided in an embodiment of the present application;

[0036] Figure 5A schematic structural diagram of an AC terminal from another perspective provided in an embodiment of the present application;

[0037] Figure 6 A schematic diagram of a structure of connecting an AC terminal and a power distribution terminal provided in one embodiment of the present application;

[0038] Figure 7 A schematic diagram of another structure of connecting an AC terminal and a power distribution terminal provided in an embodiment of the present application;

[0039] Figure 8 A schematic diagram of the structure of another AC terminal provided in an embodiment of the present application;

[0040] Fig. 9 A schematic diagram of another structure of connecting an AC terminal and a power distribution terminal provided in an embodiment of the present application;

[0041] Fig.10 A partial structural schematic diagram of another power conversion device provided by an embodiment of the present application from a perspective;

[0042] Fig.11 for Fig.10 The exploded structural diagram of the power conversion device shown;

[0043] Fig.12 A partial structural schematic diagram of another power conversion device provided in one embodiment of the present application from another perspective.

[0044] Description of reference numerals:

[0045] A-first direction, B-second direction, C-third direction, 10-housing, 11-bottom plate, 111-through hole, 112-first matching portion, 113-second matching portion, 12-cover plate, 13-side plate, 20-circuit board, 21-positioning hole, 22-assembly hole, 30-AC terminal, 31-substrate, 311-groove, 32-electrical connector, 321-pin, 322-threaded hole, 33-mounting portion, 34-first baffle, 35-positioning column, 36-support portion, 37-mounting hole, 3 8-second baffle, 40a-first fastener, 40b-second fastener, 50a-first seal, 50b-second seal, 60-distribution terminal, 61-one end of the distribution terminal, 62-the other end of the distribution terminal, 70-waterproof cover, 71-sealing surface, 72-opening, 100-power conversion device, 100a-photovoltaic inverter, 100b-energy storage converter, 200-photovoltaic module, 300-box substation, 400-boosting station, 500-power grid, 600-energy storage system. DETAILED DESCRIPTION

[0046] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings.

[0047] See also Figure 1 , Figure 1 A schematic diagram of the networking of a photovoltaic storage system in a large ground power station or industrial and commercial application scenario provided by an embodiment of the present application. Among them, the photovoltaic module 200 converts solar energy into direct current through the photovoltaic effect, and the photovoltaic inverter 100a converts the direct current output by the photovoltaic module 200 into alternating current and further transmits the alternating current to the box-type substation 300. After the box-type substation 300 converts the low-voltage alternating current output by the photovoltaic inverter 100a into medium-voltage alternating current, it further transmits the alternating current to the booster station 400 (grid 500) or the box-type substation 300 corresponding to the energy storage system 600. The energy storage system 600 is used to store unstable electrical energy from the photovoltaic module 200, and outputs stable electrical energy to the grid 500 through the energy storage converter 100b and the corresponding box-type substation 300. It can be understood that the energy storage system 600 includes an energy storage battery, and the direct current of the energy storage battery is converted into alternating current through the energy storage converter.

[0048] Figure 1 In the photovoltaic storage system shown, the photovoltaic inverter 100a and the energy storage converter 100b are the core devices for power conversion, which are collectively referred to as the power conversion device 100. The structure of the power conversion device 100 provided by the present application will be specifically described in conjunction with the accompanying drawings. It is worth mentioning that the power conversion device 100 provided by the present application can also be applied to household photovoltaic systems. Figure 1 Similarly, this application will not be repeated.

[0049] See also Figure 2 and Figure 3 , Figure 2 A schematic diagram of the structure of a power conversion device 100 provided in one embodiment of the present application. Figure 3 for Figure 2 A schematic diagram of a partially exploded structure of a power conversion device 100 is shown. The power conversion device 100 includes a housing 10, a circuit board 20, an AC terminal 30, a first fastener 40a and a first seal 50a. The housing 10 contains a portion of the circuit board 20 and the AC terminal 30. The circuit board 20 is connected and fixed to the AC terminal 30 to achieve electrical connection. The AC terminal 30 passes through the housing 10, and the portion of the AC terminal 30 located outside the housing 10 is used to connect to the power grid 500 or the load. The first fastener 40a is used to fix the AC terminal 30 to the housing 10. The first seal 50a is arranged between the AC terminal 30 and the housing 10 and is used to waterproof and seal the connection between the AC terminal 30 and the housing 10.

[0050] The housing 10 includes a bottom plate 11 , a cover plate 12 and a side plate 13 . The bottom plate 11 and the cover plate 12 are arranged relatively spaced apart along a first direction A. The side plate 13 connects an edge of the bottom plate 11 and an edge of the cover plate 12 .

[0051] The bottom plate 11 is provided with a through hole 111 and a first matching portion 112. The through hole 111 is used to allow a portion of the AC terminal 30 to extend out of the housing 10 to connect to the power grid 500 or the load. The first matching portion 112 is matched with the first fastener 40a to connect and fix the AC terminal 30 to the housing 10.

[0052] The through hole 111 penetrates two opposite sides of the bottom plate 11 along the first direction A. Correspondingly, the first sealing member 50 a is arranged around the outer periphery of the through hole 111 and surrounds the portion of the AC terminal 30 outside the housing 10 to waterproof and seal the connection between the AC terminal 30 and the bottom plate 11 .

[0053] The first matching portion 112 may be a blind hole, and the first matching portion 112 is disposed on the side of the bottom plate 11 facing the circuit board 20. The size of the first matching portion 112 along the first direction A is smaller than the size of the bottom plate 11, so that the first fastener 40a will not penetrate the bottom plate 11 and extend out of the housing 10, and there is no need to perform waterproof treatment at the connection between the first fastener 40a and the bottom plate 11, which is beneficial to improving the waterproof sealing performance of the power conversion device 100. Alternatively, the first matching portion 112 may be a combination of a connecting column and an opening, and the connecting column is provided with an opening, so that the connection strength between the bottom plate 11 and the first fastener 40a can be strengthened, which is beneficial to improving the connection reliability between the bottom plate 11 and the AC terminal 30. Among them, the connecting column can be convexly disposed on the side of the bottom plate 11 facing the circuit board 20, and the size of the opening along the first direction A is smaller than the size of the connecting column and the bottom plate 11, or smaller than the size of the connecting column. The connecting post can also be protruded on the side of the bottom plate 11 away from the circuit board 20, and a hole is opened along the first direction A to penetrate the bottom plate 11 and extend to the connecting post. The size of the hole along the first direction A is smaller than the size of the bottom plate 11 and the connecting post.

[0054] The circuit board 20 is located between the bottom plate 11 and the cover plate 12. Specifically, the circuit board 20 can be arranged relatively parallel to the cover plate 12. The circuit board 20 can be a power board for carrying components such as capacitors and inductors, or carrying power modules, etc.

[0055] The circuit board 20 is provided with a positioning hole 21 and an assembly hole 22. The positioning hole 21 is used to connect and cooperate with the AC terminal 30 to position the AC terminal 30. The assembly hole 22 is spaced apart from the positioning hole 21. The assembly hole 22 is used for one end of the AC terminal 30 to pass through so as to connect (such as weld) the AC terminal 30 to the circuit board 20 and fix it.

[0056] There are multiple positioning holes 21, for example, there are two positioning holes 21, and the two positioning holes 21 are arranged diagonally. It can be understood that the number of positioning holes 21 can be more than two, and there is no specific limitation.

[0057] Part of the AC terminal 30 extends from the bottom plate 11 outside the shell 10, which is beneficial to reducing the distance between the bottom plate 11 and the cover plate 12 along the first direction A, and is beneficial to reducing the size of the part of the shell 10 where the AC terminal 30 is installed along the first direction A, thereby facilitating improving the overall power density of the power conversion device 100, relative to the AC terminal 30 extending from the side plate 13.

[0058] Please combine Figure 4 , Figure 4 A structural schematic diagram of an AC terminal 30 provided in one embodiment of the present application from one perspective. In one embodiment, the AC terminal 30 includes a substrate 31, a plurality of electrical connectors 32, a plurality of mounting portions 33 corresponding to the plurality of electrical connectors 32, a plurality of first baffles 34, a positioning column 35, a support portion 36, and a mounting hole 37. The plurality of mounting portions 33, the plurality of first baffles 34, the positioning column 35, the support portion 36, and the mounting hole 37 may all be provided on the substrate 31.

[0059] The output current-passing terminal in the inverter is a common device for realizing electrical connection between the inverter and other electronic and electrical equipment (such as the power grid 500 or the load). The output current-passing terminal is usually connected to the circuit board 20 inside the inverter through a cable, and the large size of the shell of the current-passing terminal makes it impossible to further reduce the cavity of the whole machine, which greatly limits the improvement of power density.

[0060] The sizes of components such as capacitors and inductors carried by the circuit board 20 along the first direction A are different. Usually, the distance between the circuit board 20 and part of the bottom plate 11 along the first direction A is determined according to the component with the largest size, resulting in low utilization of the internal space of the housing 10.

[0061] Along the first direction A, the substrate 31 is arranged between the circuit board 20 and the bottom plate 11. The substrate 31 is a flat plate structure. The substrate 31 is parallel to the circuit board 20 and the bottom plate 11. A plurality of electrical connectors 32 penetrate the substrate 31 and are connected and fixed to the substrate 31. One end of the electrical connector 32 penetrates the circuit board 20 and is connected and fixed to the circuit board 20 to achieve electrical connection. One end of the electrical connector 32 extends to the circuit board 20 and is connected and fixed to the circuit board 20 by welding to achieve electrical connection. There is no cable installation between the AC terminal 30 and the circuit board 20, which is conducive to reducing the space occupancy rate in the housing 10 and reducing the size restriction of the power conversion device 100 along the first direction A. The other end of the electrical connector 32 is used to connect the power grid 500 or the load. The other end of the electrical connector 32 penetrates the substrate 31 and extends out of the housing 10 from the bottom plate 11, which can effectively reduce the distance between the part of the bottom plate 11 where the AC terminal 30 is installed and the circuit board 20 along the first direction A, which is conducive to further reducing the local size of the housing 10 along the first direction A, thereby facilitating the improvement of the overall power density of the power conversion device 100.

[0062] No cable conversion is required between the AC terminal 30 and the circuit board 20 , which simplifies the manufacturing process and is easy to install, which is beneficial to improving the assembly accuracy of the AC terminal 30 , and can effectively reduce the connection power consumption, which is beneficial to reducing the EMC risk of the power conversion device 100 .

[0063] The base plate 31 , the plurality of mounting portions 33 , the plurality of first baffles 34 , the positioning posts 35 and the supporting portion 36 are an integrally formed structure, and specifically can be connected into an integral structure by means of integral injection molding.

[0064] In one embodiment, a mounting hole 37 is provided on the substrate 31, and the mounting hole 37 passes through two opposite sides of the substrate 31 along the first direction A. The first fastener 40a passes through the mounting hole 37 and is connected and fixed to the first matching portion 112 on the bottom plate 11. The first fastener 40a does not pass through the circuit board 20, which can effectively reduce the stress risk of the first fastener 40a on the circuit board 20. Alternatively, the first fastener 40a passes through the circuit board 20 and the mounting hole 37 and is connected and fixed to the first matching portion 112.

[0065] In another embodiment, the substrate 31 and the mounting portion 33 are integrally provided with a mounting hole 37, that is, the mounting hole 37 passes through the mounting portion 33 and the substrate 31. In this case, the first fastener 40a passes through the mounting portion 33 and the substrate 31 in sequence and is connected and fixed to the first matching portion 112. In this way, the space occupied by the first fastener 40a in the housing 10 is optimized, which is conducive to improving the space utilization of the power conversion device 100.

[0066] Optionally, the first fastener 40a may pass through the circuit board 20 and the mounting hole 37 in sequence to be connected and fixed to the base plate 11.

[0067] A first seal 50a is provided between the substrate 31 and the bottom plate 11. One side of the substrate 31 facing the bottom plate 11 is in contact with one side of the first seal 50a along the first direction A, and one side of the bottom plate 11 facing the substrate 31 is in contact with the other side of the first seal 50a along the first direction A. The first seal 50a surrounds a plurality of electrical connectors 32, and the number of the first seal 50a can be set to one. The plurality of electrical connectors 32 are waterproofly sealed by one first seal 50a, and there is no need to seal each electrical connector 32 separately, which effectively reduces the influence of the manufacturing tolerance of different seals on the sealing effect, and effectively improves the waterproof sealing performance of the first seal 50a on the power conversion device 100.

[0068] Specifically, the first fastener 40a can be used to squeeze the substrate 31 and the bottom plate 11 to squeeze the first seal 50a, so that the two opposite sides of the first seal 50a along the first direction A are tightly attached to the substrate 31 and the bottom plate 11, respectively, which is beneficial to improve the airtightness of the installation interface between the substrate 31 and the bottom plate 11.

[0069] Further, at least one of the substrate 31 and the bottom plate 11 is provided with a groove 311, and the groove 311 is used to install the first sealing member 50a. For example, the substrate 31 is provided with a groove 311 on a side facing the bottom plate 11; for another example, the bottom plate 11 is provided with a groove 311 on a side facing the substrate 31; for another example, the substrate 31 is provided with a groove 311 on a side facing the bottom plate 11 and on a side facing the substrate 31. The groove 311 positions and limits the installation of the first sealing member 50a, thereby reducing the displacement of the first sealing member 50a and affecting the waterproof sealing performance.

[0070] A plurality of mounting portions 33 are protrudingly disposed on a side of the substrate 31 away from the circuit board 20, and the plurality of mounting portions 33 are arranged in an array. Each mounting portion 33 is embedded with an electrical connector 32 and is used to insulate and protect a portion of the electrical connector 32.

[0071] The electrical connector 32 and the mounting part 33 can be connected as a whole through insert injection molding. Specifically, the molded electrical connector 32 is placed in a mold for the injection molding mounting part 33, and the injection molding material of the mounting part 33 is poured into the mold, and the mounting part 33 and the electrical connector 32 are connected as a whole, thereby improving the airtightness of the electrical connector 32 and the mounting part 33.

[0072] Please combine Figure 5 , Figure 5This is a structural schematic diagram of an AC terminal 30 provided in another perspective according to an embodiment of the present application. A pin 321 is provided on the electrical connector 32, and the pin 321 passes through the assembly hole 22 of the circuit board 20 and is welded and fixed to the circuit board 20. Specifically, the electrical connector 32 is arranged vertically with the circuit board 20, and the distance from the circuit board 20 to the electrical connector 32 is small, which effectively improves the space utilization of the power conversion device 100, thereby facilitating the improvement of the power density of the power conversion device 100.

[0073] Please combine Figure 6 and Figure 7 , Figure 6 A schematic diagram of the structure of the connection between an AC terminal 30 and a power distribution terminal 60 provided in one embodiment of the present application. Figure 7 A schematic diagram of another structure of connecting an AC terminal 30 and a distribution terminal 60 provided in an embodiment of the present application. The power conversion device 100 further includes a plurality of distribution terminals 60 corresponding to a plurality of electrical connectors 32. The plurality of distribution terminals 60 are arranged outside the housing 10 and connected to the AC terminal 30, and are used to connect the AC terminal 30 to the power grid 500 or the load. For example, a threaded hole 322 is provided on a side of the electrical connector 32 facing away from the circuit board 20. The electrical connector 32 is fixed and electrically connected to one end 61 of the distribution terminal 60 by a threaded column, such as Figure 6 Alternatively, the electrical connector 32 is fixed and electrically connected to one end 61 of the power distribution terminal 60 by screws and nuts, as shown in FIG. Figure 7 shown.

[0074] At least a portion of the electrical connector 32 on the side facing away from the circuit board 20 is exposed from the mounting portion 33, that is, along the first direction A, the size of the electrical connector 32 is larger than the size of the mounting portion 33, so that the electrical connector 32 is connected and fixed to the end 61 of the power distribution terminal 60. The distance between two adjacent electrical connectors 32 is relatively close, which is prone to creepage hazards.

[0075] A first baffle 34 is provided between two adjacent mounting portions 33, and the first baffle 34 is used to provide insulation protection for two adjacent electrical connectors 32. Specifically, along the first direction A, the size of the first baffle 34 is larger than the size of the electrical connector 32, which effectively increases the creepage distance between the two adjacent electrical connectors 32 along the first direction A, and effectively reduces the risk of creepage.

[0076] A plurality of distribution terminals 60 extend along a second direction B, and the second direction B is perpendicular to the first direction A. Along the second direction B, one end 61 of the distribution terminal 60 is connected and fixed to the electrical connector 32, and the other end 62 of the distribution terminal 60 is located on one side of the mounting portion 33 along the second direction B, and the other end 62 of the distribution terminal 60 is connected to the power grid 500 or the load. Among them, the current direction from the circuit board 20 to the electrical connector 32 is defined as the drainage direction, and the current direction from the electrical connector 32 to the distribution terminal 60 is defined as the outflow direction. The electrical connector 32 is arranged vertically to the circuit board 20, and the distribution terminal 60 is arranged vertically to the electrical connector 32. The drainage direction is perpendicular to the outflow direction, which can effectively reduce the size of the AC terminal 30 extending out of the housing 10 along the first direction A, thereby facilitating the reduction of the size of the power conversion device 100 along the first direction A, and facilitating the improvement of the power density of the power conversion device 100.

[0077] Furthermore, along the second direction B, the size of the first baffle 34 is larger than the size of the electrical connector 32. Specifically, both ends of the first baffle 34 that are opposite to each other along the second direction B exceed both sides of the mounting portion 33 that are opposite to each other along the second direction B. In this way, the first baffle 34 can increase the creepage distance of two adjacent electrical connectors 32 along the second direction B, which is beneficial to reducing the risk of creepage.

[0078] For example, a plurality of first baffles 34 are arranged along the third direction C, that is, a plurality of mounting portions 33 are arranged along the third direction C, and first baffles 34 may be provided on both sides of the mounting portions 33 opposite to each other along the third direction C, wherein two adjacent mounting portions 33 may share one first baffle 34. The first direction A, the second direction B and the third direction C are perpendicular to each other. The first direction A may be the width direction of the power conversion device 100, and the third direction C may be the length direction of the power conversion device 100.

[0079] The positioning post 35 is convexly disposed on the side of the substrate 31 facing the circuit board 20. The positioning post 35 is used to cooperate with the positioning hole 21 on the circuit board 20. There are multiple positioning posts 35, and multiple positioning posts 35 are spaced apart at the edge of the substrate 31. The positioning posts 35 are used to achieve accurate positioning between the electrical connector 32 and the circuit board 20, which is conducive to improving the assembly efficiency of the electrical connector 32 and the circuit board 20.

[0080] The support portion 36 is protruded from the side of the substrate 31 facing the circuit board 20, and the end of the support portion 36 away from the substrate 31 abuts against the surface of the circuit board 20. The support portion 36 supports the substrate 31 and controls the welding height between the electrical connector 32 and the circuit board 20 at the same time. It can effectively absorb the tolerance of the connection between different electrical connectors 32 and the circuit board 20, which is beneficial to reduce the stress of the solder joint.

[0081] There may be one support portion 36, which is disposed around the edge of the substrate 31; or there may be multiple support portions 36, which are disposed at intervals on the edge of the substrate 31. When there are multiple support portions 36, the support portions 36 may be columnar structures.

[0082] It should be noted that the number and positions of the support parts 36 , the positioning columns 35 and the mounting holes 37 can be adjusted according to actual needs and are not specifically limited.

[0083] Please combine Figure 8 and Fig. 9 , Figure 8 A schematic diagram of the structure of another AC terminal 30 provided in an embodiment of the present application. Fig. 9 A schematic diagram of another structure of connecting an AC terminal 30 and a distribution terminal 60 provided in an embodiment of the present application. In another embodiment, the AC terminal 30 may further include a second baffle 38. The second baffle 38 and the other end 62 of the distribution terminal 60 are arranged opposite to each other in the second direction B, and the second baffle 38 is arranged on one side of the mounting portion 33 along the second direction B and connects the ends of multiple first baffles 34, that is, one end of the first baffle 34 facing the second baffle 38 along the second direction B is flush with the side of the mounting portion 33 facing the second baffle 38, and multiple first baffles 34 are connected by the second baffle 38, and the size of the first baffle 34 along the second direction B can be appropriately reduced, thereby reducing the space occupied by the AC terminal 30 in the housing 10, which is conducive to improving the power density of the power conversion device 100.

[0084] Along the first direction A, the size of the second baffle 38 is larger than the size of the electrical connector 32. For example, along the first direction A, the size of the second baffle 38 may be equal to the size of the first baffle 34. In this way, the second baffle 38 effectively blocks the creepage phenomenon of two adjacent electrical connectors 32 on the other side of the plurality of mounting portions 33 along the second direction B, further reducing the risk of creepage. Optionally, along the first direction A, the size of the second baffle 38 is different from the size of the first baffle 34. For example, the size of the second baffle 38 may be larger than the size of the first baffle 34; or, the size of the second baffle 38 is smaller than the size of the first baffle 34, and the specific details are not limited.

[0085] Please combine Fig.10 and Fig.11 , Fig.10 A partial structural diagram of another power conversion device 100 provided in an embodiment of the present application from one perspective. Fig.11 for Fig.10Schematic diagram of the exploded structure of the power conversion device 100 shown. In another embodiment, the power conversion device 100 further includes a second fastener 40b, a second seal 50b and a waterproof cover 70. The second fastener 40b is used to fix the waterproof cover 70 and the housing 10. The second seal 50b is arranged between the waterproof cover 70 and the housing 10 and is used to waterproof the connection between the waterproof cover 70 and the housing 10. The waterproof cover 70 is arranged outside the housing 10 and is used to waterproof and seal the connection between the AC terminal 30 and the housing 10.

[0086] Specifically, the waterproof cover 70 is disposed on a side of the bottom plate 11 away from the circuit board 20 and covers the through hole 111. The waterproof cover 70 accommodates multiple mounting portions 33 and multiple power distribution terminals 60. The waterproof cover 70 is added outside the housing 10 to provide waterproof protection for the part of the AC terminal 30 located outside the housing 10, thereby improving the waterproof performance of the power conversion device 100.

[0087] Please combine Fig.12 , Fig.12 A partial structural schematic diagram of another power conversion device 100 provided in an embodiment of the present application from another perspective. The waterproof cover 70 includes a sealing surface 71 and an opening 72. The sealing surface 71 is parallel to the side of the bottom plate 11 facing away from the circuit board 20, and the side of the sealing surface 71 facing the bottom plate 11 is in contact with a side of the second sealing member 50b. The sealing surface 71 is arranged to be in contact with the second sealing member 50b, which effectively improves the sealing performance between the waterproof cover 70 and the bottom plate 11. The side of the bottom plate 11 facing away from the circuit board 20 is in contact with the other side of the second sealing member 50b. Among them, the force applied to the waterproof cover 70 by the second fastener 40b when fixing the waterproof cover 70 on the bottom plate 11 can press the second sealing member 50b tightly between the sealing surface 71 and the bottom plate 11, thereby strengthening the waterproof sealing protection of the AC terminal 30.

[0088] For example, the bottom plate 11 is further provided with a second matching portion 113, and the second matching portion 113 is matched and connected with the second fastener 40b. Similarly, the second matching portion 113 can be a blind hole, wherein the second matching portion 113 is provided on the side of the bottom plate 11 facing away from the circuit board 20, and the size of the second matching portion 113 along the first direction A is smaller than the size of the bottom plate 11, so that the second fastener 40b will not penetrate the bottom plate 11 and extend into the housing 10, and there is no need to perform waterproof treatment at the connection between the second fastener 40b and the bottom plate 11, which is conducive to improving the waterproof sealing performance of the power conversion device 100. The second matching portion 113 can also be a combination of a connecting column and an opening, wherein the second matching portion 113 is convexly provided on the side of the bottom plate 11 facing the circuit board 20, and the opening penetrates the bottom plate 11 and extends to the second matching portion 113, and the connection strength between the second fastener 40b and the bottom plate 11 is strengthened without affecting the connection between the second sealing member 50b, the waterproof cover 70 and the bottom plate 11.

[0089] Among them, along the second direction B, the opening 72 is arranged opposite to the other end 62 of the distribution terminal 60; the opening 72 is used to pass the other end 62 of the distribution terminal 60; or the opening 72 is used to pass the cable connected to the other end 62 of the distribution terminal 60. Specifically, a waterproof sealing treatment can be performed at the opening 72 to strengthen the waterproof protection at the AC terminal 30, which is conducive to improving the waterproof performance of the power conversion device 100.

[0090] In this application, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0091] The first, second and various numerical numbers involved in this document are only distinguished for the convenience of description and are not intended to limit the scope of the present application.

[0092] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0093] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, a person skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A power conversion device, characterized in that: It includes a shell, a circuit board and an AC terminal. The shell includes a bottom plate and a cover plate. The bottom plate and the cover plate are arranged relative to each other along a first direction; the circuit board and the bottom plate are arranged relative to each other along the first direction and are located between the cover plate and the bottom plate; the AC terminal includes a substrate and a plurality of electrical connectors. The substrate is arranged between the bottom plate and the circuit board. The plurality of electrical connectors pass through the substrate and are connected and fixed to the substrate. One end of the electrical connector is connected and fixed to the circuit board and is electrically connected. The other end of the electrical connector is located outside the shell. The other end of the electrical connector is used to connect to a power grid or a load.

2. The power conversion device according to claim 1, characterized in that: The bottom plate is provided with a through hole, and the through hole is used to allow the other ends of the multiple electrical connectors to extend out of the shell; the power conversion device also includes a first seal, which is arranged between the substrate and the bottom plate, and the two opposite sides of the first seal along the first direction are respectively attached to the substrate and the bottom plate, and the first seal surrounds the multiple electrical connectors.

3. The power conversion device according to claim 2, characterized in that: At least one of the bottom plate and the base plate is provided with a groove, and the groove is used for installing the first sealing member.

4. The power conversion device according to any one of claims 1 to 3, characterized in that: The AC terminal also includes a plurality of mounting portions corresponding one-to-one to the plurality of electrical connectors, the plurality of mounting portions are arranged in an array, the plurality of mounting portions are protruded on a side of the substrate facing the bottom plate and are at least partially located outside the shell, and each of the mounting portions is embedded with the electrical connector.

5. The power conversion device according to claim 4, characterized in that: The AC terminal further includes a plurality of first baffles, wherein the first baffles are disposed between two adjacent mounting portions, and the size of the first baffles along the first direction is greater than the size of the electrical connector.

6. The power conversion device according to claim 5, characterized in that: The power conversion device also includes a plurality of distribution terminals corresponding one-to-one to the plurality of electrical connectors, and the plurality of distribution terminals all extend along a second direction, the second direction is perpendicular to the first direction, one end of the distribution terminal is connected and fixed to the electrical connector, and the other end of the distribution terminal is located on one side of the mounting portion along the second direction and is used to connect to the power grid or the load.

7. The power conversion device according to claim 6, characterized in that: Along the second direction, a size of the first baffle is larger than a size of the electrical connector.

8. The power conversion device according to claim 6 or 7, characterized in that: The AC terminal also includes a second baffle, which is arranged on the other side of the plurality of mounting portions along the second direction, and the second baffle connects the plurality of first baffles; along the first direction, the size of the second baffle is larger than the size of the electrical connector.

9. The power conversion device according to any one of claims 6 to 8, characterized in that: The power conversion device further comprises a waterproof cover, which is fixed to a side of the bottom plate away from the circuit board and covers a through hole of the bottom plate, and the waterproof cover accommodates a plurality of the mounting portions and a plurality of the power distribution terminals.

10. The power conversion device according to claim 9, characterized in that: The waterproof cover includes a sealing surface, which is parallel to the side of the base plate facing away from the circuit board. The power conversion device also includes a second sealing member, which surrounds the through hole of the base plate, and the second sealing member is in contact with the sealing surface along the first direction, and the second sealing member is in contact with the side of the base plate facing away from the circuit board along the first direction.

11. The power conversion device according to claim 9 or 10, characterized in that: The waterproof cover also includes an opening, and the opening is used to pass the other end of the distribution terminal.

12. The power conversion device according to any one of claims 1 to 11, characterized in that: The AC terminal further comprises a positioning post, which is protruding from a side of the base plate facing the circuit board. The circuit board is provided with a positioning hole, which is used to cooperate with the positioning post.

13. The power conversion device according to any one of claims 1 to 12, characterized in that: The AC terminal further includes a supporting portion, which is protruding from a side of the substrate facing the circuit board, and is connected to the circuit board.

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