Power module integrated with current sensor

Abstract

The utility model discloses a power module integrated with a current sensing sensor. The power module integrated with the current sensing sensor comprises the current sensing sensor and a power module. The current sensing sensor comprises a magnetic core, an insertion channel is formed in the magnetic core, the magnetic core is provided with two extending parts which are oppositely arranged, and an opening for communicating the insertion channel with the outside is formed between the two extending parts of the magnetic core. The power module comprises a substrate mechanism and a conductor assembly, the conductor assembly comprises an output conductor and positive and negative conductors, the positive and negative conductors and the output conductor are connected with the substrate mechanism, the output conductor has a preset length, the length direction of the output conductor is the same as the axis direction of the insertion channel, and the output conductor forms an assembly part, an input part and an output part; the two sides of the assembling part are each provided with a notch, the magnetic core is assembled with the output conductor in the mode that the assembling part is inserted into the inserting channel, and the two extending parts of the magnetic core are kept to be at least partially and correspondingly contained in the corresponding notches respectively.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power semiconductor, in particular to a power module integrated with a current sensing sensor. BACKGROUND

[0002] The power module is mainly used for power conversion in electric vehicles, photovoltaic power generation, wind power generation, industrial frequency conversion and the like. In actual use, the output current value of the power module needs to be obtained. However, the power module does not have the function of measuring current, so a current sensor needs to be installed on the copper bar connected with the AC output electrode of the power module to measure the output current of the power module by the current sensor.

[0003] The magnetic core of the existing current sensor forms a mounting channel for the plug-in copper bar and an opening in communication with the mounting channel. In order to be successfully installed, the cross-sectional dimension of the copper bar along the width direction thereof needs to be matched with the size of the mounting channel formed by the magnetic core. Generally, the cross-sectional dimension of the copper bar along the width direction thereof is proportional to the maximum current that the copper bar can withstand. It can be understood that the larger the cross-sectional dimension of the copper bar along the width direction thereof, the larger the size of the magnetic core that needs to be matched. In actual use, some power modules need to pass a larger current. In this case, the copper bar provided by the power module is wider, and accordingly, the size of the magnetic core matched with the copper bar is larger to meet the requirement of detecting large current, which undoubtedly increases the use cost and causes the combination of the power module and the current sensor after assembly to require a larger installation space, which is not conducive to actual use. CONTENT OF THE UTILITY MODEL

[0004] To solve the above technical problems and achieve at least one advantage of the present application, the present application provides a power module integrated with a current sensing sensor, which comprises:

[0005] A current sensing sensor, which comprises a magnetic core and a Hall chip, the magnetic core forms a mounting channel, the magnetic core has two extending parts arranged oppositely, the magnetic core forms an opening in communication with the outside between the two extending parts, the Hall chip has a chip body and a plurality of pins, one end of the pin is connected with the chip body, and the chip body of the Hall chip partially extends into the mounting channel through the opening.

[0006] The power module comprises a substrate mechanism and a conductor assembly, the conductor assembly comprises an output conductor and positive and negative conductors, the positive and negative conductors and the output conductor are electrically connected with the substrate mechanism, the output conductor has a preset length, wherein the length direction of the output conductor is the same as the axis direction of the insertion channel, the output conductor has a notch formed at the corresponding position on both sides along the length direction, the two extension portions of the magnetic core are at least partially correspondingly accommodated in the corresponding notches, and the output conductor is interposed between the two extension portions and penetrates the insertion channel.

[0007] According to an embodiment of the present application, the output conductor forms an assembly portion, an input portion and an output portion, wherein the input portion is electrically connected with the substrate mechanism, and the assembly portion is located between the input portion and the output portion, both sides of the assembly portion form a notch, so that the width of the assembly portion is smaller than the width of the input portion and the output portion, and the magnetic core is assembled with the output conductor in a manner that the assembly portion is inserted into the insertion channel.

[0008] According to an embodiment of the present application, the width of the assembly portion is smaller than the spacing between the inner walls of the two extension portions forming the opening portion, and the output conductor is moved into the insertion channel from the opening along the thickness direction of the output conductor relative to the magnetic core.

[0009] According to an embodiment of the present application, one side of the substrate mechanism forms a conversion portion, the input portion and the positive and negative conductors are electrically connected with the conversion portion, the power module further comprises a shell, the shell forms a hidden space, the shell is coveringly installed on the substrate mechanism and keeps the conversion portion hidden in the hidden space formed by the shell, and the output conductor and the positive and negative conductors extend to the outside from the hidden space through the shell.

[0010] According to an embodiment of the present application, the shell comprises a side plate and a cover plate, the side plate and the cover plate jointly form the hidden space, the side plate surrounds the circumferential side of the conversion portion, the substrate mechanism blocks one of the openings formed by the side plate, and the cover plate is installed on the side of the side plate away from the substrate mechanism and blocks the other opening formed by the side plate.

[0011] According to an embodiment of the present application, the substrate mechanism further has a plurality of connection terminals, the connection terminals are electrically connected with the conversion portion, the cover plate forms a plurality of avoiding channels, and the connection terminals penetrate the avoiding channels.

[0012] According to an embodiment of the present application, the shell comprises a plurality of buckles, at least two of which are oppositely arranged, and the cover plate and the side plate are formed by the buckles or are detachably arranged by buckling.

[0013] According to an embodiment of the present application, the power module of the integrated current sensing sensor further comprises a PCB board, the PCB board is connected with the cover plate by a fastener, and the connection terminal and the pin of the Hall chip are both electrically connected with the PCB board.

[0014] According to an embodiment of the present application, the assembling part is formed on the part of the output conductor extending into the shell, the side plate forms a mounting groove corresponding to the opening position, and the Hall chip electrically connected with the PCB board extends into the opening formed by the magnetic core through the mounting groove.

[0015] According to an embodiment of the present application, the assembling part is formed on the part of the output conductor extending into the shell BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 The structural schematic diagram of the power module of the integrated current sensing sensor is shown.

[0017] Figure 2 The structural explosion diagram of the power module of the integrated current sensing sensor is shown.

[0018] Figure 3 The structural explosion diagram of the magnetic core and the output conductor in an embodiment is shown.

[0019] Figure 4 The structural explosion diagram of the magnetic core and the output conductor in another embodiment is shown.

[0020] Figure 5 The sectional view of the power module of the integrated current sensing sensor is shown.

[0021] Figure 6 The structural schematic diagram of the shell is shown. DETAILED DESCRIPTION

[0022] The following description is provided to enable any person skilled in the art to practice the present application. The preferred embodiments in the following description are only examples of implementing the present application and other obvious modifications are possible to those skilled in the art. The principles defined in the following description can be applied to other embodiments, variations, improvements, equivalents and other technical solutions without departing from the spirit and scope of the present application.

[0023] Those skilled in the art will understand that the terms "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate an orientation or positional relationship based on the orientation or positional relationship shown in the drawings, which are merely for convenience of description and simplification of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore the above terms cannot be understood as a limitation on the present application.

[0024] It can be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of one element can be one, and in another embodiment, the number of the element can be multiple, and the term "one" cannot be understood as a limitation on the number.

[0025] Reference Figures 1 to 6 The power module of the integrated current sensing sensor of a preferred embodiment of the present application will be described in detail below. The power module of the integrated current sensing sensor includes a current sensing sensor 10 and a power module 20.

[0026] The current sensing sensor 10 includes a magnetic core 11, which forms an insertion channel 1101. The magnetic core 11 has two extensions 111 arranged oppositely, and the magnetic core 11 forms an opening 1102 between the two extensions 111 to communicate the insertion channel 1101 with the outside.

[0027] The power module 20 includes a substrate mechanism 21 and a conductor assembly 22, which includes an output conductor 221 and positive and negative conductors 222, which are electrically connected to the substrate mechanism 21. The output conductor 221 has a predetermined length, wherein the length direction of the output conductor 221 is the same as the axis direction of the insertion channel 1101. The output conductor 221 forms a notch 22101 at a corresponding position on both sides along the length direction, and the two extensions 111 of the magnetic core 11 are at least partially accommodated in the corresponding notch 22101, and the output conductor 221 is between the two extensions 111, so that the output conductor 221 penetrates the insertion channel 1101.

[0028] Specifically, the output conductor 221 has an input portion 2211, an assembly portion 2212 and an output portion 2213, wherein the input portion 2211 is electrically connected with the substrate mechanism 21, and the assembly portion 2212 is located between the input portion 2211 and the output portion 2213. The assembly portion 2212 has a width smaller than that of the input portion 2211 and the output portion 2213. The width of the assembly portion 2212 is smaller than the distance between the inner walls of the insertion channel 1101 formed by the two extension portions 111, and the magnetic core 11 is assembled with the output conductor 221 by inserting the assembly portion 2212 into the insertion channel 1101. The notches 22101 provide accommodation spaces for the two extension portions 111 of the magnetic core 11 along the width direction of the assembly portion 2212, thereby reducing the volume of the magnetic core 11 and the power module of the integrated current sensing sensor.

[0029] It can be understood that, based on the fact that the input portion 2211 and the output portion 2213 of the output conductor 221 have the same width as the copper bar in the prior art, the width of the assembly portion 2212 is smaller than that of the copper bar in the prior art. In the case of passing through the same size current, the magnetic circuit formed at the assembly portion 2212 is shorter, the magnetic resistance is smaller, the energy loss is less, and therefore the magnetic flux is larger. Therefore, in the case of reducing the volume of the magnetic core 11, the current sensor 10 can detect the same size current, while ensuring the detection effect and reducing the manufacturing cost of the power module of the integrated current sensing sensor. In addition, when the magnetic core 11 and the magnetic core made of the same material as the existing copper bar have the same weight, the current sensor 10 can detect a larger current while the size of the magnetic core 11 is reduced.

[0030] In the case of the same size of the magnetic core 11, the input portion 2211 and the output portion 2213 of the output conductor 221 assembled with the magnetic core 11 are wider than those in the prior art. In the case of the same thickness, the cross-sectional area of the input portion 2211 and the output portion 2213 along the width direction is larger, i.e. the maximum current allowed to pass through the output conductor 221 is increased, and therefore the current range actually measured by the current sensing sensor 10 is larger. Compared with the prior art, the current sensor 10 with a small size can be used to detect a large current, thereby further reducing the manufacturing cost of the power module of the integrated current sensing sensor.

[0031] Preferably, the width of the assembly portion 2212 is less than the distance between the inner walls of the two extension portions 111 forming the opening 1102.

[0032] Specifically, the output conductor 221 is moved into the insertion channel 1101 from the opening 1102 along the thickness direction of the output conductor 221 relative to the magnetic core 11. In assembly, the opening 1102 formed by the magnetic core 11 is aligned with the assembly portion 2212 first, and then the magnetic core 11 is moved relative to the output conductor 221 along the thickness direction of the output conductor 221 to assemble the two, which is more simple and fast compared with the prior art.

[0033] Preferably, after the magnetic core 11 and the output conductor 221 are assembled, the dimension of the magnetic core 11 along the width direction of the output conductor 221 is not more than the width of the input portion 2211 and the output portion 2213, so that the extension portion 111 is at least partially completely inserted into the corresponding notch 22101, so that the size of the shell 23 does not need to be enlarged.

[0034] Further, the current sensing sensor 10 further comprises a Hall chip 12, the Hall chip 12 has a chip body 121 and a plurality of pins 122, one end of the pin 122 is connected with the chip body 121, and the chip body 121 of the Hall chip 12 is partially inserted into the insertion channel 1101 through the opening 1102.

[0035] Specifically, one side of the substrate mechanism 21 forms a conversion portion 211, and the output conductor 221 and the positive and negative conductors 222 are electrically connected with the conversion portion 211.

[0036] Further, the power module 20 further comprises a shell 23, the shell 23 forms a hidden space 2301, the shell 23 is coveringly installed on the substrate mechanism 21 and keeps the conversion portion 211 hidden in the hidden space 2301 formed by the shell 23, wherein the output conductor 221 and the positive and negative conductors 222 are both inserted into the outside from the hidden space 2301 through the shell 23 to connect with external wires.

[0037] Specifically, the shell 23 comprises a side wall plate 231 and a cover plate 232, and the side wall plate 231 and the cover plate 232 jointly form the hidden space 2301. The side wall plate 231 surrounds the circumferential side of the conversion portion 211, so that the substrate mechanism 21 blocks one opening formed by the side wall plate 231. The cover plate 232 is installed on the side of the side wall plate 231 away from the substrate mechanism 21, to block the other opening formed by the side wall plate 231.

[0038] It is worth mentioning that the substrate mechanism 21 further has a plurality of connection terminals 212 electrically connected with the conversion part 211. The cover plate 232 forms a plurality of avoiding passages 23201 through which the connection terminals 212 pass.

[0039] Preferably, the shell 23 comprises a plurality of buckles 233, at least two of which are oppositely arranged. The cover plate 232 and the side plate 231 are formed on the buckles 233, or are detachably arranged by buckling the buckles 233, so as to cover or expose the conversion part 211 for subsequent maintenance.

[0040] Preferably, the substrate mechanism 21 further forms a plurality of mounting holes 2101 through which fasteners, for example, screws, are connected with a fixing object.

[0041] Further, the power module of the integrated current sensing sensor further comprises a PCB 30 connected with the cover plate 232 by fasteners. The connection terminals 212 and the pins 122 of the Hall chip 12 extending out of the end of the hidden space 2301 are both electrically connected with the PCB 30.

[0042] In an embodiment, the assembling part 2212 is formed on the portion of the output conductor 221 extending out of the shell 23.

[0043] In another embodiment, the assembling part 2212 is formed on the portion of the output conductor 221 extending into the shell 23. The side plate 231 forms a mounting groove 23102 corresponding in position to the opening 1102, and the Hall chip 12 electrically connected with the PCB 30 extends into the opening 1102 formed by the magnetic core 11 through the mounting groove 23102. Compared with the previous embodiment, this embodiment integrates the magnetic core 11 inside the shell 23, shortens the length of the output conductor 221 extending out of the shell 23, and reduces the size of the PCB 30, thereby reducing the volume of the power module of the integrated current sensing sensor.

[0044] Those skilled in the art should understand that the embodiments of the present application described above and shown in the drawings are only examples and do not limit the present application. The advantages of the present application have been fully and effectively achieved. The functional and structural principles of the present application have been shown and described in the embodiments, and the embodiments of the present application can be modified or changed in any way without departing from the principles.

Claims

1. Power module with integrated current sensing sensor, characterized in that, The power module of the integrated current sensing sensor comprises: a current sensing sensor, which comprises a magnetic core and a Hall chip, the magnetic core forms an insertion channel, the magnetic core has two oppositely arranged extensions, and the magnetic core forms an opening between the two extensions to communicate the insertion channel with the outside; a power module, which comprises a substrate mechanism and a conductor assembly, the conductor assembly comprises an output conductor and positive and negative conductors, the positive and negative conductors and the output conductor are electrically connected with the substrate mechanism, the output conductor has a preset length, the length direction of the output conductor is the same as the axis direction of the insertion channel, and the output conductor forms a notch at a corresponding position on each side along the length direction, and the two extensions of the magnetic core are at least partially accommodated in the corresponding notches, respectively, and the output conductor is between the two extensions and penetrates the insertion channel.

2. The power module of claim 1, wherein, The output conductor forms an assembly part, an input part and an output part, the input part is electrically connected with the substrate mechanism, the assembly part is between the input part and the output part, each side of the assembly part forms a notch, the width of the assembly part is smaller than the width of the input part and the output part, and the magnetic core is assembled with the output conductor in a way that the assembly part is inserted into the insertion channel.

3. The power module of claim 2, wherein the integrated current sense sensor is a Hall effect sensor. The width of the assembly part is smaller than the spacing between the inner walls of the two extensions forming the opening part, and the output conductor moves into the insertion channel from the opening along the thickness direction of the output conductor relative to the magnetic core.

4. The power module of claim 3, wherein, One side of the substrate mechanism forms a conversion part, the input part and the positive and negative conductors are electrically connected with the conversion part, the power module further comprises a shell, the shell forms a hidden space, the shell is coveringly installed on the substrate mechanism and keeps the conversion part hidden in the hidden space formed by the shell, and the output conductor and the positive and negative conductors extend to the outside from the hidden space through the shell.

5. The power module of claim 4, wherein the integrated current sense sensor is a Hall effect sensor. The shell comprises a side wall plate and a cover plate, the side wall plate and the cover plate jointly form the hidden space, the side wall plate surrounds the circumferential side of the conversion part, the substrate mechanism blocks one port formed by the side wall plate, and the cover plate is installed on the side of the side wall plate away from the substrate mechanism and blocks another port formed by the side wall plate.

6. The power module of claim 5, wherein, The substrate mechanism further has a plurality of connection terminals, the connection terminals are electrically connected with the conversion part, the cover plate forms a plurality of avoiding channels, and the connection terminals penetrate the avoiding channels.

7. The power module of claim 6, wherein the integrated current sense sensor is a Hall effect sensor. The shell comprises a plurality of buckles, at least two buckles are oppositely arranged, and the cover plate and the side wall plate are formed in the buckles or are detachably assembled by buckling the buckles.

8. The power module of claim 7, wherein the integrated current sense sensor is a Hall effect sensor. The power module of the integrated current sensing sensor further comprises a PCB plate connected with the cover plate through fasteners, and the connecting terminals and the pins of the Hall chip extending out of the end of the hidden space through the avoiding channels are electrically connected with the PCB plate.

9. The power module of claim 8, wherein the integrated current sense sensor is a Hall effect sensor. The assembling part is formed at the part of the output conductor extending into the shell, the side wall plate forms a mounting groove corresponding to the opening position, and the Hall chip electrically connected with the PCB plate extends into the opening formed by the magnetic core through the mounting groove.

10. The power module of claim 8, wherein the integrated current sense sensor is a Hall effect sensor. The assembling part is formed at the part of the output conductor extending out of the shell.

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