Power converter and power system

Abstract

The application discloses a power converter and a power system, and relates to the technical field of power electronics. The power converter comprises a shell; a power board is arranged in the shell, the power board has a first surface and a second surface which are oppositely arranged in a first direction, and a power device and a reactor are arranged on the first surface; the reactor comprises a reactor body and two conductive terminals arranged on the reactor body; a hollow part extending along the first direction is arranged on the power board, and the hollow part is arranged in correspondence with the conductive terminals; an output board is arranged at one side of the second surface in a spaced mode, and a conductive part is arranged on the surface of the output board away from the power board; two groups of electric connection assemblies are arranged, and at least part of the electric connection assemblies is arranged in the space between the power board and the output board; the electric connection assembly comprises a first connection terminal and a second connection terminal; the first connection terminal is electrically connected with the power board and the conductive terminals, and the connecting part of the first connection terminal and the conductive terminals penetrates through the hollow part; and the second connection terminal is electrically connected with the conductive part.

Description

Technical Field

[0001] This application relates to the field of power electronics technology, and in particular to a power converter and power system. Background Technology

[0002] In fields such as photovoltaic power generation, energy storage systems, and industrial power electronics, power converters serve as core devices for converting and controlling electrical energy. They typically integrate power boards, output boards, and electronic components (such as reactors and power devices). The power boards and output boards are vertically spaced within the power converter's housing, and they achieve power transmission and signal interaction through an electrical connection structure.

[0003] However, in some technologies, the reactor is mounted on one side of the power board, and its conductive terminals are exposed on the outer periphery of the power board. That is, in a cross-section perpendicular to the first direction, the conductive terminals are not shielded by the power board but extend outwards into the empty area inside the housing. This arrangement requires reserving installation space within the housing perpendicular to the first direction for arranging the conductive terminals and electrical connection structures. This installation space encroaches on space within the housing that could otherwise be used to arrange other functional modules, thereby reducing the space utilization rate inside the power converter. Utility Model Content

[0004] This application provides a power converter and power system to at least partially solve the above-mentioned technical problems.

[0005] To achieve the above objectives, according to a first aspect of this application, a power converter is provided, comprising: case; A power board is disposed inside a housing. The power board has a first surface and a second surface that are arranged opposite each other in a first direction, as well as a power device and a reactor mounted on the first surface. The reactor includes a reactor body and two conductive terminals disposed on the reactor body. The power board is provided with a hollow portion extending along the first direction, and the hollow portion is disposed corresponding to the conductive terminals. The output board is spaced apart on one side of the second surface, and a conductive part is provided on the surface of the output board opposite to the power board; An electrical connection assembly has two sets, and at least part of them are located in the gap between the power board and the output board; the electrical connection assembly includes a first connection terminal and a second connection terminal, the first connection terminal is electrically connected to both the power board and the conductive terminal, and the connection portion of the first connection terminal and the conductive terminal passes through the hollow portion, and the second connection terminal is electrically connected to the conductive portion.

[0006] In some embodiments of this application, an electronic device is disposed on the second surface, and the electrical connection assembly includes an electrical connection bar having a first segment and a second segment. A first connection terminal is electrically connected to the second segment through the first segment. The second segment extends in a direction parallel to the power board and is electrically connected to a conductive part through the second connection terminal. The distance between the second segment and the second surface is greater than the size of the electronic device in the first direction.

[0007] In some embodiments of this application, there are N reactors arranged at intervals along a second direction, and there are N groups of electrical connection components, wherein N≥2; The second segment of the electrical connection bar in each group of electrical connection components is spaced apart in at least one of the second and third directions; The second direction, the third direction, and the first direction are mutually perpendicular, and the second direction and the third direction are both parallel to the power board.

[0008] In some embodiments of this application, the electrical connection assembly further includes a first support portion disposed between the power board and the second segment to insulate and support the second segment on the second surface.

[0009] In some embodiments of this application, the second segment has a connection end that is away from the first segment; the connection end is electrically connected to the conductive part through a second connection terminal; the electrical connection assembly further includes a second support part disposed between the power board and the connection end to insulate and support the connection end on the second surface.

[0010] In some embodiments of this application, the orthographic projection area of ​​the connection portion between the connection end and the second connection terminal on the power board is located outside the orthographic projection area of ​​the output board on the power board.

[0011] In some embodiments of this application, the second connection terminal is formed by a conductive busbar and includes a first connection segment, a second connection segment, and a main body segment; the first connection segment is electrically connected to the connection end; the second connection segment is located on the side of the output board opposite to the power board and is electrically connected to the conductive part; the main body segment extends along a first direction and is electrically connected to the first connection segment and the second connection segment, and the main body segment is spaced apart on the outer periphery of the output board.

[0012] In some embodiments of this application, the housing has a bottom plate and a top plate disposed opposite each other in a first direction, and the power converter further includes: The pallet is spaced between the top and bottom plates and connected to the housing; wherein... The power board is mounted on the base plate, the output board is mounted on the side of the tray facing away from the power board, and at least part of the electrical connection assembly is located in the gap between the power board and the tray.

[0013] In some embodiments of this application, a clearance opening is provided on the base plate, the reactor body is disposed on the side of the base plate opposite to the power board, and at least some of the conductive terminals extend into the interior of the housing through the clearance opening.

[0014] In some embodiments of this application, two hollowed-out portions corresponding to two conductive terminals electrically connected to the same reactor body on the power board are located in the same area of ​​the orthogonal projection of the clearance opening on the base plate.

[0015] In some embodiments of this application, the reactor further includes: The limiting structure includes a support member and a limiting member. The support member is connected between the limiting member and the reactor body to rigidly support the limiting member on the side of the conductive terminal facing away from the reactor body. When the first connecting terminal is assembled with the conductive terminal, the limiting member is used to restrict the movement of the first connecting terminal toward the conductive terminal.

[0016] In some embodiments of this application, the limiting member is provided with a limiting hole that extends along a first direction, and the conductive terminal and the first connecting terminal are respectively located on opposite sides of the limiting member in the first direction; the electrical connection assembly also includes an electrical connector that passes through the limiting hole to electrically connect the first connecting terminal and the conductive terminal.

[0017] In some embodiments of this application, the first connection terminal includes a first electrically conductive part and a second electrically conductive part connected together, the electrical connector electrically connects the first electrically conductive part and the conductive terminal, and the electrical connection position of the second electrically conductive part and the power board is located on the outer periphery of the hollow part.

[0018] In some embodiments of this application, an electrical conduction portion is provided on the power board. The electrical conduction portion is located on the outer periphery of the corresponding hollow portion and is electrically connected to the second electrical conduction portion.

[0019] In some embodiments of this application, the first electrically conductive portion is flat and at least partially disposed within the hollow portion; the second electrically conductive portion includes two straight segments and a bent segment; both straight segments extend in a first direction, and the end of one straight segment near the power board is electrically connected to the first electrically conductive portion, the end of the other straight segment near the power board is electrically connected to the power board, and the bent segment is electrically connected to the ends of the two straight segments away from the power board; or, The first conductive part is suspended on the second surface, and the second conductive part is bent relative to the first conductive part.

[0020] In some embodiments of this application, when the first electrically conductive portion is suspended on the second surface, at least a portion of the electrical connector is disposed within the gap between the first electrically conductive portion and the conductive terminal; or, the conductive terminal extends out of the second surface through a corresponding hollow portion, and the side of the limiting member facing away from the conductive terminal abuts against the first electrically conductive portion.

[0021] In some embodiments of this application, the power board has an outer wall connecting the first surface and the second surface, and a cutout is disposed near the outer wall and simultaneously penetrates the first surface, the second surface and the outer wall.

[0022] In some embodiments of this application, the housing has a base plate facing the first surface, and the base plate has a window. The power converter further includes: The heat dissipation device is located on the side of the base plate opposite to the power board and is thermally connected to the power device through a window.

[0023] According to a second aspect of this application, a power system is provided, the power system comprising: The power converter described in any of the above technical solutions.

[0024] In the power converter of this application embodiment, the reactor is disposed on the first surface of the power board through the above-described technical solution. Its conductive terminals form a vertical electrical connection with the first connection terminal of an electrical connection assembly located on the other side of the power board (i.e., the second surface) through a pre-drilled cutout on the power board. This cutout creates an efficient connection channel between the two sides of the power board. With this design, the conductive terminals no longer need to extend outwards along the outer periphery of the power board, thereby freeing up the peripheral space originally occupied by the conductive terminals and their connection structures within the housing, thus improving the utilization efficiency of the internal space of the power converter. Simultaneously, at least a portion of the two sets of electrical connection assemblies are arranged within the gap between the power board and the output board, preventing the space between the power board and the output board in the first direction from being idle. This achieves full utilization of the internal space of the housing, optimizes the spatial configuration between the power board and the output board, and further improves the utilization rate of the internal space of the power converter.

[0025] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0027] Figure 1 This is an exploded view of a power converter according to an embodiment of this application; Figure 2This is a cross-sectional view of a power converter according to an embodiment of this application; Figure 3 yes Figure 2 An enlarged schematic diagram of part A in the middle; Figure 4 This is an assembly diagram of the power board and electrical connection components in a power converter according to an embodiment of this application; Figure 5 This is a partial perspective view of a power converter according to an embodiment of this application; Figure 6 This is a perspective view of a reactor in a power converter according to an embodiment of this application; Figure 7 This is a perspective view of the first connection terminal in a power converter according to an embodiment of this application; Figure 8 This is a top view of a power board in a power converter according to an embodiment of this application; Figure 9 This is a top view of another power board in a power converter according to an embodiment of this application; Figure 10 This is a cross-sectional view of another power converter in an embodiment of this application; Figure 11 yes Figure 10 Enlarged schematic diagram of part B in the middle; Figure 12 This is an assembly diagram of the power board and electrical connection components in another power converter according to an embodiment of this application; Figure 13 This is a cross-sectional view of yet another power converter in the embodiments of this application; Figure 14 yes Figure 13 An enlarged schematic diagram of section C; Figure 15 This is an assembly diagram of the power board and electrical connection components in another power converter according to an embodiment of this application.

[0028] Explanation of reference numerals in the attached figures: 1-Shell; 11-Bottom plate; 111-Apartment opening; 112-Window; 12-Top plate; 2-Power board; 21-First surface; 22-Second surface; 23-Power device; 24-Reactor; 241-Reactor body; 242-Conductive terminal; 243-Limiting structure; 2431-Support member; 2432-Limiting member; 2433-Limiting hole; 25-Clearing part; 26-Electronic device; 27-Electrically conductive part; 28-Outer wall surface; 3-Output board; 31-Conductive part; 4-Electrical connection assembly; 41-First connection terminal; 411-First electrical conduction part; 4111-Mounting hole; 412-Second electrical conduction part; 4121-Straight section; 4122-Bent section; 42-Second connection terminal; 421-First connection section; 422-Second connection section; 423-Main body section; 43-Electrical connection bar; 431-First section; 432-Second section; 4321-Connecting end; 4322-Extension sub-section; 4323-Connecting sub-section; 44-First support part; 45-Second support part; 46-Electrical connector; 5-Tray; 6-Heat dissipation components; Z - First direction; X - Second direction; Y - Third direction. Detailed Implementation

[0029] 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, and 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.

[0030] In the description of this application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0031] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0032] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; or they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0033] This application provides a power converter and a power system, which will be described in detail below. It should be noted that the order of description of the following embodiments is not intended to limit the preferred order of the embodiments of this application. Furthermore, the descriptions of each embodiment have their own emphasis; parts not described in detail in a certain embodiment can be referred to in the relevant descriptions of other embodiments.

[0034] In fields such as photovoltaic power generation, energy storage systems, and industrial power electronics, power converters serve as core devices for converting and controlling electrical energy. They typically integrate power boards, output boards, and electronic components (such as reactors and power devices). The power boards and output boards are vertically spaced within the power converter's housing, and they achieve power transmission and signal interaction through an electrical connection structure.

[0035] However, in some technologies, the reactor is mounted on one side of the power board, and its conductive terminals are exposed on the outer periphery of the power board. That is, in a cross-section perpendicular to the first direction, the conductive terminals are not shielded by the power board but extend outwards into the empty area inside the housing. This arrangement requires reserving installation space within the housing perpendicular to the first direction for arranging the conductive terminals and electrical connection structures. This installation space encroaches on space within the housing that could otherwise be used to arrange other functional modules, thereby reducing the space utilization rate inside the power converter.

[0036] like Figures 1 to 3 As shown, the power converter includes a housing 1, a power board 2, an output board 3, and an electrical connection assembly 4. The power board 2 is disposed within the housing 1 and has a first surface 21 and a second surface 22 disposed opposite each other in a first direction Z, and power devices 23 and reactors 24 mounted on the first surface 21. The reactor 24 includes a reactor body 241 and two conductive terminals 242 disposed on the reactor body 241. The power board 2 has cutouts 25 corresponding to the conductive terminals 242. The output board 3 is spaced apart on one side of the second surface 22, and conductive portions 31 are disposed on the surface of the output board 3 facing away from the power board 2. The electrical connection assembly 4 has two sets, and is at least partially located within the gap between the power board 2 and the output board 3. Each electrical connection assembly 4 includes a first connection terminal 41 and a second connection terminal 42. The first connection terminal 41 is electrically connected to the power board 2 and to the conductive terminal 242. The connection portion of the first connection terminal 41 and the conductive terminal 242 passes through the hollow portion 25. The second connection terminal 42 is electrically connected to the conductive portion 31.

[0037] In this technical solution, the reactor 24 is disposed on the first surface 21 of the power board 2. Its conductive terminal 242 forms a vertical electrical connection with the first connection terminal 41 of the electrical connection assembly 4 located on the other side of the power board 2 (i.e., the second surface 22 side) through a pre-opened cutout 25 on the power board 2. The cutout 25 constructs an efficient connection channel between the two sides of the power board 2. With the above design, the conductive terminal 242 no longer needs to extend outward along the outer periphery of the power board 2, thereby freeing up the outer peripheral space inside the housing 1 originally occupied by the conductive terminal 242 and its connection structure, thus improving the utilization efficiency of the internal space of the power converter. At the same time, at least a portion of the two sets of electrical connection assemblies 4 are arranged in the gap between the power board 2 and the output board 3, avoiding the space of the power board 2 and the output board 3 in the first direction Z being idle, realizing the full utilization of the internal space of the housing 1, optimizing the spatial configuration between the power board 2 and the output board 3, and further improving the utilization rate of the internal space of the power converter.

[0038] Specifically, the housing 1 internally houses the power board 2, the output board 3, and the electrical connection assembly 4. The reactor 24 includes a reactor body 241 and two conductive terminals 242 disposed on the reactor body 241. One of the two conductive terminals 242 is an input conductive terminal 242, and the other is an output conductive terminal 242. Both conductive terminals 242 are electrically connected to the power board 2 and the output board 3, and when viewed along the first direction Z, the conductive terminals 242 are located within the area covered by the edge of the power board 2. The first surface 21 of the power board 2 is mainly used to mount power devices 23 (such as MOSFETs and IGBTs) with relatively high heat generation, as well as components such as the reactor 24. The output board 3 is located on one side of the second surface 22 of the power board 2, i.e. Figure 2 It is positioned above the power board 2 shown, and spaced apart from the power board 2.

[0039] For example, the orthographic projection of the conductive terminal 242 onto the first surface 21 along the first direction Z completely falls within the projection range of the cutout portion 25 onto the first surface 21. The first direction Z is the thickness direction of the power board 2. That is, the conductive terminal 242 and the cutout portion 25 on the power board 2 are aligned in the first direction Z, so that at least a portion of at least one of the first connecting terminal 41 and the conductive terminal 242, or the electrical connector 46 connecting the two, can pass through the cutout portion 25 to achieve vertical electrical interconnection between the first connecting terminal 41 and the conductive terminal 242 in the first direction Z, thereby making full use of the space in the first direction Z and avoiding space waste caused by planar wiring.

[0040] Please combine Figure 1 and Figure 4In this embodiment, the second surface 22 is provided with electronic devices 26, and the electrical connection assembly 4 includes an electrical connection bar 43. The electrical connection bar 43 has a first segment 431 and a second segment 432. A first connection terminal 41 is electrically connected to the second segment 432 through the first segment 431. The second segment 432 extends in a direction parallel to the power board 2 and is electrically connected to the conductive part 31 through the second connection terminal 42. The distance between the second segment 432 and the second surface 22 is greater than the dimension of the electronic device 26 in the first direction Z. This ensures that the second segment 432 of the electrical connection bar 43 has sufficient clearance above the second surface 22, avoiding interference between the second segment 432 of the electrical connection bar 43 and the electronic device 26. At the same time, since the second segment 432 maintains sufficient vertical spacing from the second surface 22, the electronic device 26 mounted on the second surface 22 does not need to be offset to avoid the electrical connection assembly 4, thereby achieving a compact arrangement of the electronic device 26 on the second surface 22. Furthermore, the above arrangement can, to some extent, prevent the second segment 432 from being too close to the electronic device 26, thereby helping to reduce the risk of electrical coupling and interference between the high current path and the electronic device 26.

[0041] As an example, there are N reactors 24, spaced apart along the second direction X, and N groups of electrical connection assemblies 4, where N ≥ 2. The second segment 432 of the electrical connection bar 43 in each group of electrical connection assemblies 4 is spaced apart along the second direction X and / or the third direction Y. The second direction X, the third direction Y, and the first direction Z intersect each other, and both the second direction X and the third direction Y are parallel to the power board 2. The first segment 431 is used to achieve the electrical connection between the second segment 432 and the first connection terminal 41. When multiple reactors 24 are integrated within the power converter, by spaced apart the second segment 432 of each group of electrical connection assemblies 4 in at least one of the second direction X and the third direction Y, sufficient horizontal or vertical spacing can be maintained between the second segments 432 of adjacent electrical connection bars 43, avoiding contact, overlap, or electrical short circuit problems caused by space compression. For example, the first direction Z can be the thickness direction of the power board 2, the second direction X can be the length direction of the power board 2, and the third direction Y can be the width direction of the power board 2.

[0042] Figure 4 The image only shows an example of the second segment 432 of the three electrical connection rows 43 in the three sets of electrical connection assemblies 4 being spaced out in the third direction Y. Combined with Figure 1 and Figure 4As can be seen, the conductive portion 31 on the output board 3 is disposed on the side surface of the output board 3 facing away from the power board 2, and is arranged close to the edge (left edge) of the output board 3 in the second direction X. Based on this arrangement, the closer the reactor 24 is to the conductive portion 31 in the second direction X, the shorter the extension length of the second segment 432 of the electrical connection assembly 43 connected to the reactor 24 in the second direction X. Conversely, the farther the reactor 24 is from the conductive portion 31 in the second direction X, the longer the extension length of the second segment 432 of the electrical connection assembly 43 in the second direction X.

[0043] Meanwhile, since multiple reactors 24 are arranged at intervals along the second direction X, the first segment 431 of the electrical connection bar 43 is connected to the conductive terminals 242 of the reactors 24 through the first connection terminal 41. The physical position of the first segment 431 of the electrical connection bar 43 is indirectly constrained by the interval arrangement of the reactors 24 in the second direction X, and is also arranged at intervals along the second direction X, corresponding one-to-one with the arrangement order and position of the reactors 24.

[0044] Please continue to refer to Figure 4 In this embodiment, the electrical connection assembly 4 further includes a first support portion 44, which is disposed between the power board 2 and the second segment 432 to insulately support the second segment 432 on the second surface 22. The second segment 432 (e.g., the extension sub-segment 4322) has a relatively longer extension length than the first segment 431, making it susceptible to vibration, thermal expansion and contraction, or external stress during power converter operation. The first support portion 44 provides reliable mechanical support for the second segment 432 through physical contact with the power board 2 and the second segment 432, preventing loosening, displacement, or sagging during long-term operation. This ensures a stable spatial position on the second surface 22 of the power board 2, thereby improving the long-term reliability of the electrical connection of the electrical connection assembly 4 and reducing the risk of poor contact, open circuits, or localized overheating.

[0045] Please combine Figure 4 and Figure 5The electrical connection assembly 4 also includes a second support portion 45, and the second segment 432 has a connection end 4321 located away from the first segment 431. The connection end 4321 is electrically connected to the conductive portion 31 via a second connection terminal 42. The second support portion 45 is disposed between the power board 2 and the connection end 4321 to insulate and support the connection end 4321 on the second surface 22. The connection end 4321 is the connection point when the second segment 432 is electrically connected to the second connection terminal 42. The second support portion 45 restricts the free movement of the connection end 4321 through physical support, ensuring a stable mating position between the connection end 4321 and the second connection terminal 42. This effectively avoids the risk of poor contact or open circuit caused by mechanical displacement, improving the reliability and stability of the electrical connection path.

[0046] It is understood that the first support portion 44 and the second support portion 45 can be integrally formed from the electrical connector 43 through a bending process. In this structure, it is only necessary to ensure that the connection areas between the first support portion 44 and the second support portion 45 and the power board 2 do not constitute an electrical conductive path, that is, to maintain effective electrical isolation between the two and the power board 2. This achieves the mechanical support function while avoiding the risk of short circuits or electrical interference caused by accidental contact or the formation of a conductive path. In some embodiments, the first support portion 44 and the second support portion 45 can also be support studs, which are fixedly installed on the power board 2, and their top ends are electrically connected to the corresponding positions of the electrical connector 43. The support studs are mechanically connected to both the electrical connector 43 and the power board 2, meaning that there is no electrical conductive path between them.

[0047] like Figure 5 As shown, the projection area of ​​the connection point between the connector 4321 and the second connector 42 on the power board 2 is outside the projection area of ​​the output board 3 on the power board 2. This provides a more spacious working area for the assembly of the connector 4321 and the second connector 42, effectively avoiding operational difficulties caused by space constraints, and thus improving the assembly efficiency and ease of operation. Specifically, the connector 4321 is positioned on the power board 2 outside the projection area of ​​the output board 3 (or tray 5) on the power board 2.

[0048] In some embodiments, the second connection terminal 42 is constructed via a conductive busbar and includes a first connection segment 421, a second connection segment 422, and a main body segment 423. The first connection segment 421 is electrically connected to the connection end 4321. The second connection segment 422 is located on the side of the output board 3 facing away from the power board 2 and is electrically connected to the conductive portion 31. The main body segment 423 extends along the first direction Z and is electrically connected to the first connection segment 421 and the second connection segment 422. The main body segments 423 are spaced apart on the outer periphery of the output board 3. Thus, on the one hand, a continuous and stable electrical connection path is constructed from the connection end 4321 of the electrical connection assembly 4 to the conductive portion 31. On the other hand, the main body segment 423 extends along the first direction Z, effectively connecting the connection end 4321 on the side of the power board 2 and the conductive portion 31 on the output board 3 through a vertical conductive path, ensuring low impedance and low loss during the transmission of high current or high power signals, and improving the reliability and current carrying capacity of the overall electrical connection of the power converter. Meanwhile, the main body section 423 and the outer periphery of the output board 3 are arranged at a distance, which avoids the need to set up an installation channel on the output board 3 during the electrical connection process between the second connection terminal 42 and the conductive part 31, and helps to simplify the electrical connection between the two.

[0049] Specifically, both the first connecting segment 421 and the second connecting segment 422 extend parallel to the first direction Z. For example, the second connecting terminal 42 is Z-shaped, but it can also be U-shaped or S-shaped with a bent recessed structure, which is used to avoid the output board 3 and / or tray 5.

[0050] Please combine Figure 1 and Figure 5 The housing 1 has a top plate 12 and a bottom plate 11 disposed opposite each other in a first direction Z. The power converter also includes a tray 5, which is spaced between the top plate 12 and the bottom plate 11 and connected to the housing 1. The power board 2 is disposed on the bottom plate 11, and the output board 3 is disposed on the side of the tray 5 opposite to the power board 2. At least a portion of the electrical connection assembly 4 is located within the gap between the power board 2 and the tray 5. The tray 5 provides a mounting platform for the output board 3 and maintains a controllable distance between it and the power board 2. By physically separating the output board 3 from the power board 2 through the tray 5, interference from electromagnetic noise, thermal radiation, or mechanical stress on the sensitive circuits on the output board 3 can be effectively blocked, improving the system's electromagnetic compatibility and operational reliability.

[0051] It should be noted that, in the embodiment where the power converter includes tray 5, the main body segment 423 is simultaneously and spaced apart on the outer periphery of both the output board 3 and tray 5. For example... Figure 5 As shown, the main body segment 423 is located to the left of the output plate 3 and the tray 5, and the left edge of the tray 5 is closer to the main body segment 423 than the left edge of the output plate 3.

[0052] Please continue to refer to Figure 2 and Figure 3 The base plate 11 has a clearance opening 111. The reactor body 241 is located on the side of the base plate 11 facing away from the power board 2, and at least some of the conductive terminals 242 extend into the interior of the housing 1 through the clearance opening 111. Thus, the conductive terminals 242 extend directly to the vicinity of the power board 2 through the clearance opening 111, shortening the physical connection distance between the reactor 24 and the power board 2, and reducing stray inductance and resistance in the circuit. Furthermore, the reactor body 241 is typically equipped with a heat dissipation structure (such as heat sink fins, heat conduction grooves, or a metal heat dissipation surface). By placing it on the side of the base plate 11 facing away from the power board 2 (usually the lower area of ​​the housing 1), i.e., installing it on the outside of the housing 1, it can effectively dissipate the heat generated by the reactor 24 during operation to the external environment.

[0053] If each conductive terminal 242 were provided with a separate clearance opening 111, multiple independent openings would need to be made on the base plate 11, increasing the processing complexity of the housing 1. Therefore, in this application, two conductive terminals 242 of the same reactor 24 are inserted into the interior of the housing 1 through the same clearance opening 111 to reduce the number of openings and thus reduce processing costs. Furthermore, the design of a single clearance opening 111 provides a unified operating entry point for the installation and connection of the conductive terminals 242 of the reactor 24, reducing the positioning difficulty and operating steps during the assembly process.

[0054] In some embodiments, two cutouts 25 are provided on the power board 2 corresponding to the two conductive terminals 242 of the same reactor 24. The orthographic projection areas of these two cutouts 25 on the base plate 11 are located within the orthographic projection area of ​​the same clearance opening 111 on the base plate 11. The two conductive terminals 242 of the reactor 24 can be simultaneously introduced into the housing 1 through a single clearance opening 111, eliminating the need to align multiple independent openings during assembly and reducing the positioning difficulty during assembly. Simultaneously, although the two conductive terminals 242 share the same clearance opening 111 to enter the housing 1, they achieve independent electrical connection through their corresponding cutouts 25. That is, each conductive terminal 242 has its own dedicated mounting channel, ensuring physical isolation of the electrical path. This design effectively suppresses electromagnetic crosstalk between the two conductive terminals 242, reduces interference from external electromagnetic noise on the connection path, and further improves the electromagnetic compatibility of the power converter.

[0055] Please combine Figure 3 and Figure 6The reactor 24 also includes a limiting structure 243, which includes a support member 2431 and a limiting member 2432. The support member 2431 is connected between the limiting member 2432 and the reactor body 241 to rigidly support the limiting member 2432 on the side of the conductive terminal 242 facing away from the reactor body 241. When the first connecting terminal 41 is assembled with the conductive terminal 242, the limiting member 2432 abuts against the first connecting terminal 41 to restrict the movement of the first connecting terminal 41 toward the conductive terminal 242. In other words, the limiting structure 243 provides a positioning reference for the assembly connection of the first connecting terminal 41 and the conductive terminal 242, provides an assembly boundary for the first connecting terminal 41, and restricts further movement of the first connecting terminal 41 toward the conductive terminal 242 through mechanical contact, preventing the conductive terminal 242 from being subjected to excessive pressure during assembly, which could cause bending, deformation, or damage. The limiting member 2432 restricts the excessive force exerted by the first connecting terminal 41 on the conductive terminal 242, protecting the structural integrity of the conductive terminal 242 and ensuring that its electrical performance is not affected. The first connecting terminal 41 and the conductive terminal 242 can be electrically connected by methods such as crimping, welding, or bolting. For example, the limiting structure 243 is approximately L-shaped and is an integral part of the reactor body 241.

[0056] As an example, the limiting member 2432 is provided with a limiting hole 2433 extending along the first direction Z. The conductive terminal 242 and the first connecting terminal 41 are respectively located on opposite sides of the limiting member 2432 in the first direction Z. The electrical connection assembly 4 also includes an electrical connector 46, which passes through the limiting hole 2433 to electrically connect the first connecting terminal 41 and the conductive terminal 242. The limiting hole 2433 on the limiting member 2432 provides a guiding path for the electrical connector 46, ensuring that the electrical connector 46 can accurately pass through the limiting member 2432 along the first direction Z, so that the first connecting terminal 41 and the conductive terminal 242 can be reliably connected at a preset position. During the assembly process, the directional guidance of the limiting hole 2433 allows the electrical connector 46 to be inserted along the first direction Z, ensuring that the electrical connector 46 can be precisely aligned with the connection point of the conductive terminal 242 after passing through the limiting hole 2433, thereby simplifying the assembly process and improving production efficiency.

[0057] It should be noted that the limiting member 2432 restricts the movement of the first connecting terminal 41 toward the conductive terminal 242. In some embodiments, this can be achieved by the first connecting terminal 41 abutting against the conductive terminal 242. For example, the first connecting terminal 41 and the conductive terminal 242 can be in direct contact, or they can be indirectly contacted through abutting members provided on the first connecting terminal 41 or the conductive terminal 242. For example... Figure 4 As shown, the first connecting terminal 41 directly abuts against the end face of the limiting member 2432 that is opposite to the conductive terminal 242.

[0058] Please combine Figure 3 , Figure 7 and Figure 8 The first connection terminal 41 includes a first conductive part 411 and a second conductive part 412 connected together. An electrical connector 46 electrically connects the first conductive part 411 to the conductive terminal 242. The electrical connection position of the second conductive part 412 to the power board 2 is located on the outer periphery of the cutout portion 25. Specifically, the first conductive part 411 and the second conductive part 412 are physically connected to form an integrated structure, but each performs different electrical connection functions. This partitioned design avoids mutual interference between different electrical connection functions, allowing current to be efficiently transmitted along its optimal path, reducing impedance and energy loss during transmission, and improving the overall power conversion efficiency and electrical performance stability of the power converter.

[0059] like Figure 7 and Figure 8 As shown, the power board 2 is provided with an electrical conductive section 27, which is located on the outer periphery of the corresponding cutout section 25 and is electrically connected to the second electrical conductive section 412. The electrical conductive section 27 provides precise installation positioning for the second electrical conductive section 412. During assembly, the operator can quickly locate the connection position of the second electrical conductive section 412 through the electrical conductive section 27 on the outer periphery of the cutout section 25, achieving precise docking (such as welding, crimping, or riveting) without additional measurement or complex alignment operations. For example, the electrical conductive section 27 includes, but is not limited to, solder pads, copper foil traces, vias, or conductive blocks.

[0060] Please continue to refer to Figure 3 The base plate 11 has a window 112. The power converter also includes a heat sink 6, which is located on the side of the base plate 11 facing away from the power board 2 and is thermally connected to the power device 23 through the window 112. In practical use, the power device 23 (such as IGBT, MOSFET, etc.) generates a large amount of heat during the operation of the power converter. The window 112 on the base plate 11 and the heat sink 6 allow for efficient thermal connection with the power device 23, either directly or through a thermal interface material (such as thermal grease or a thermal pad). This creates a short, low-resistance thermal conduction path between the power device 23 and the heat sink 6, accelerating the transfer of heat from the surface of the power device 23 to the heat sink 6, thereby improving the heat dissipation efficiency of the power device 23, ensuring stable operation of the power device 23 within a suitable temperature range, and enhancing the reliability and durability of the power converter. For example, the heat sink 6 can be a heat sink, heat pipe, cooling plate, heat sink fins, or thermal pad.

[0061] In the embodiment where the reactor body 241 is located on the side of the base plate 11 facing away from the power plate 2, and the power converter also includes a heat dissipation device 6, both the reactor body 241 and the heat dissipation device 6 are located below the top plate 12, that is, on the side of the base plate 11 facing away from the power plate 2. This concentrates the heat dissipation function of the power converter in the lower area of ​​the housing 1, reduces the complexity of the thermal management system, makes thermal management more efficient, centralized and easy to implement, and helps to improve the stability and reliability of the system under high temperature conditions.

[0062] like Figure 9 As shown, the power board 2 has an outer wall 28 connecting the first surface 21 and the second surface 22. A cutout 25 is disposed near the outer wall 28 and simultaneously penetrates the first surface 21, the second surface 22, and the outer wall 28. That is, the projection shape of the cutout 25 on the first surface 21 is approximately U-shaped. The conductive terminal 242 can be directly inserted into the cutout through the opening of the U-shaped cutout, providing a more direct and intuitive access path for the assembly operation of the conductive terminal 242 and the electrical connection assembly 4. Of course, as... Figure 8 As shown, the hollow part 25 is located near the outer wall surface 28 and only penetrates the first surface 21 and the second surface 22. That is, the hollow part 25 is a hollow hole, and the outer contour of its projection shape on the first surface 21 is continuous and uninterrupted.

[0063] The differences in the power converters of various embodiments of this application will be described in detail below with reference to the accompanying drawings. The differences between the embodiments include: the bending form of the electrical connection bar 43, the structure of the first connection terminal 41, and the connection method between the first connection terminal 41 and the conductive terminal 242.

[0064] Example 1 like Figure 4 As shown, in this embodiment, the extension direction of the first segment 431 is perpendicular to the second surface 22 of the power board 2. The dimension of the first segment 431 in the first direction Z directly determines the vertical distance between the second segment 432 and the second surface 22. That is, by controlling the length of the first segment 431 in the first direction Z, it can be ensured that a sufficient distance is maintained between the second segment 432 and the second surface 22, so that this distance is greater than that of the electronic device 26 (see reference numerals). Figure 2 The dimensions in the first direction Z provide sufficient clearance for the second segment 432 above the second surface 22 to avoid structural interference between the second segment 432 and the electronic device 26.

[0065] Furthermore, the second segment 432 includes an extension segment 4322 and a connecting segment 4323. The extension segment 4322 connects the first segment 431 and the connecting segment 4323, and the end of the connecting segment 4323 away from the extension segment 4322 forms the connecting end 4321. Each second connecting terminal 42 is positioned consistently in the second direction X and is spaced apart along the third direction Y. Both the extension segments 4322 and the connecting segments 4323 are located in the same reference plane parallel to the power board 2. The extension segments 4322 extend along the third direction Y, and the length of each extension segment 4322 in the third direction Y is gradient-designed, that is, the extension segment 4322 further away from the second connecting terminal 42 is longer, so that the extension segments 4322 are staggered in the third direction Y, effectively avoiding structural interference between adjacent extension segments 4322.

[0066] like Figure 3 and Figure 7 As shown, the first electrical conductive portion 411 is flat and at least partially disposed within the cutout portion 25. The second electrical conductive portion 412 includes two straight sections 4121 and a bent section 4122. Both straight sections 4121 extend in a first direction Z, and the end of one straight section 4121 near the power board 2 is electrically connected to the first electrical conductive portion 411, while the end of the other straight section 4121 near the power board 2 is electrically connected to the power board 2. The bent section 4122 electrically connects the ends of the two straight sections 4121 away from the power board 2. The bending design of the bent section 4122 allows the electrical connection assembly 4 to adapt to installation errors during assembly through its own deformation (such as slight bending), converting the concentrated stress originally acting on the power board 2 into elastic deformation of the second electrical conductive portion 412, thereby reducing the stress on the power board 2 during installation and protecting the structural integrity of the power board 2.

[0067] As an example, the cross-sectional shape of the second electrical conductive section 412 in the section perpendicular to the third direction Y is approximately "U". The bent segment 4122 in the U-shape can compensate for manufacturing tolerances that may exist in the electrical conductive section 27 on the power board 2 through its own deformation capability (such as slight stretching, compression or deflection), so that the first connecting terminal 41 and the electrical conductive section 27 of the power board 2 can achieve reliable contact without strict and precise alignment, reducing the risk of assembly failure due to the accumulation of tolerances.

[0068] In this embodiment, the first electrically conductive part 411 is provided with a mounting hole 4111 extending along the first direction Z, and the electrical connector 46 is a fastener that passes through the mounting hole 4111 and the limiting hole 2433 (see reference numerals) in sequence. Figure 6After that, it is threadedly connected to the crimp nut pre-installed on the conductive terminal 242. The mounting hole 4111 and the limiting hole 2433 together form a guide path in the first direction Z, guiding the fastener to pass precisely along the first direction Z, ensuring that the first electrical conductive part 411, the limiting part 2432 and the conductive terminal 242 are strictly aligned in the first direction Z, avoiding poor contact or misalignment caused by assembly misalignment.

[0069] Example 2 Please combine Figures 10 to 12 The first conductive portion 411 is suspended on the second surface 22, and the second conductive portion 412 is bent relative to the first conductive portion 411. Thus, the second conductive portion 412 can achieve its function through a simple bend (e.g., extending towards the power board 2 along the first direction Z after bending), simplifying the overall structure of the first connecting terminal 41. This eliminates the need for high-precision multi-angle machining or complex molds, reducing manufacturing costs and production complexity. For example, the cross-sectional shape of the first connecting terminal 41 in the section perpendicular to the third direction Y is approximately U-shaped, with the opening facing towards the power board 2.

[0070] In this embodiment, at least a portion of the electrical connector 46 is disposed within the gap between the first conductive portion 411 and the conductive terminal 242, shortening the current transmission path length and reducing stray inductance and resistance in the circuit. Simultaneously, placing the electrical connector 46 within the gap ensures a more stable relative position between it and the first conductive portion 411 and the conductive terminal 242. Through the support or tight fit of the electrical connector 46, the relative fixation of the first conductive portion 411 and the conductive terminal 242 is guaranteed, reducing the risk of connection loosening or poor contact due to vibration and enhancing the long-term reliability of the connection. For example, the electrical connector 46 can be a wire, a conductive post, or a conductive bolt.

[0071] For example, the electrical connector 46 is a conductive post. The bottom end of the conductive post extends through the cutout 25 and the limiting hole 2433 to the bottom of the power board 2 and is threadedly connected to the crimp nut in the conductive terminal 242. The top end of the conductive post is provided with an internal threaded hole. The first connecting terminal 41 also includes a fastening screw, which passes through the first electrical conductive part 411 and is threadedly connected to the internal threaded hole. Alternatively, the top end of the conductive post is directly welded to the first electrical conductive part 411.

[0072] Continue to refer to Figure 12The first segment 431 extends parallel to the second surface 22 of the power board 2. The size of the first segment 431 in the first direction Z directly determines the misalignment distance of the adjacent second segments 432 in the third direction Y. For example, the length of each first segment 431 in the third direction Y is designed in a gradient manner, that is, the length of the first segment 431 that is further away from the second connection terminal 42 (i.e., the end of the second segment 432 that is furthest away from the first segment 431) is longer, so that each second segment 432 is staggered in the third direction Y, effectively avoiding structural interference between adjacent second segments 432.

[0073] Furthermore, the second segment 432 includes an extension segment 4322 and a connecting segment 4323, with the connecting segment 4323 bent away from the power board 2 along the first direction Z. In other words, by controlling the length of the connecting segment 4323 in the first direction Z, it is possible to ensure that a sufficient distance is maintained between the extension segment 4322 and the second surface 22, such that this distance is greater than the size of the electronic device in the first direction Z, thus avoiding structural interference between the connecting segment 4323 and the electronic device.

[0074] Example 3 Combination Figures 13 to 15 The difference between this embodiment and embodiment two is that the conductive terminal 242 extends out of the second surface 22 through the corresponding hollow part 25, and the side of the limiting member 2432 facing away from the conductive terminal 242 abuts against the first electrical conductive part 411, reducing the setting of additional connecting parts (such as independent support frame, positioning block), making the connection structure between the conductive terminal 242, the limiting member 2432 and the first electrical conductive part 411 more compact, and further reducing the height and volume of the overall structure.

[0075] In some embodiments of this application, a power system is also provided, which includes a power converter as described in any of the above technical solutions. Since the power converter in this power system has the same technical features as the power converter described above, both can solve the same technical problems and achieve the same technical effects.

[0076] 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.

[0077] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope 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 protection of the claims. Furthermore, specific examples have been used in the specification to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application, and the content of this specification should not be construed as a limitation of this application.

Claims

1. A power converter, characterized in that, The power converter includes: case; A power board is disposed within the housing. The power board has a first surface and a second surface disposed opposite each other in a first direction, and power devices and reactors mounted on the first surface. The reactor includes a reactor body and two conductive terminals disposed on the reactor body. The power board is provided with a hollow portion extending along the first direction, and the hollow portion is disposed corresponding to the conductive terminals. An output board is spaced apart on one side of the second surface, and a conductive portion is provided on the surface of the output board facing away from the power board; An electrical connection assembly has two sets, and at least part of them are located in the gap between the power board and the output board; the electrical connection assembly includes a first connection terminal and a second connection terminal, the first connection terminal is electrically connected to both the power board and the conductive terminal, and the connection portion of the first connection terminal and the conductive terminal passes through the hollow portion, and the second connection terminal is electrically connected to the conductive portion.

2. The power converter according to claim 1, characterized in that, The second surface is provided with electronic devices, and the electrical connection assembly includes an electrical connection bar having a first segment and a second segment. The first connection terminal is electrically connected to the second segment through the first segment. The second segment extends in a direction parallel to the power board and is electrically connected to the conductive part through the second connection terminal. The distance between the second segment and the second surface is greater than the size of the electronic device in the first direction.

3. The power converter according to claim 2, characterized in that, The reactors are N in number and are spaced apart along the second direction; the electrical connection components are N in number, where N ≥ 2. The second segment of the electrical connection row in each group of electrical connection assemblies is spaced apart in at least one of the second direction and the third direction; The second direction, the third direction, and the first direction intersect each other, and both the second direction and the third direction are parallel to the power board.

4. The power converter according to claim 2, characterized in that, The electrical connection assembly further includes a first support portion disposed between the power board and the second segment to insulate and support the second segment on the second surface.

5. The power converter according to claim 2, characterized in that, The second segment has a connection end that is away from the first segment, and the connection end is electrically connected to the conductive part through the second connection terminal; The electrical connection assembly further includes a second support portion disposed between the power board and the connection end to insulate and support the connection end on the second surface.

6. The power converter according to claim 5, characterized in that, The connection point between the connection end and the second connection terminal is located outside the orthographic projection area of ​​the output board on the power board.

7. The power converter according to claim 5, characterized in that, The second connection terminal is formed by a conductive busbar and includes a first connection segment, a second connection segment, and a main body segment; the first connection segment is electrically connected to the connection terminal; the second connection segment is located on the side of the output board opposite to the power board and is electrically connected to the conductive part; the main body segment extends along the first direction and is electrically connected to the first connection segment and the second connection segment, and the main body segment is spaced apart on the outer periphery of the output board.

8. The power converter according to any one of claims 1 to 7, characterized in that, The housing has a bottom plate and a top plate disposed opposite each other in the first direction, and the power converter further includes: A tray, spaced apart between the top and bottom plates, is connected to the housing; wherein... The power board is disposed on the base plate, the output board is disposed on the side surface of the tray opposite to the power board, and at least a portion of the electrical connection assembly is located within the gap between the power board and the tray.

9. The power converter according to claim 8, characterized in that, An opening is provided on the base plate, the reactor body is disposed on the side of the base plate opposite to the power board, and at least a portion of the conductive terminals extend into the interior of the housing through the opening.

10. The power converter according to claim 9, characterized in that, The two hollowed-out portions on the power board, which are electrically connected to the same reactor body, are located in the same area of ​​the orthogonal projection of the clearance opening on the base plate.

11. The power converter according to any one of claims 1 to 7, characterized in that, The reactor also includes: The limiting structure includes a support member and a limiting member. The support member is connected between the limiting member and the reactor body to rigidly support the limiting member on the side of the conductive terminal facing away from the reactor body. When the first connecting terminal is assembled with the conductive terminal, the limiting member restricts the movement of the first connecting terminal toward the conductive terminal.

12. The power converter according to claim 11, characterized in that, The limiting member is provided with a limiting hole that extends along the first direction, and the conductive terminal and the first connecting terminal are respectively located on opposite sides of the limiting member in the first direction; the electrical connection assembly further includes an electrical connector, which passes through the limiting hole to electrically connect the first connecting terminal and the conductive terminal.

13. The power converter according to claim 12, characterized in that, The first connection terminal includes a first electrically conductive part and a second electrically conductive part connected together. The electrical connector electrically connects the first electrically conductive part and the conductive terminal. The electrical connection position of the second electrically conductive part and the power board is located on the outer periphery of the hollow part.

14. The power converter according to claim 13, characterized in that, The power board is provided with an electrical conduction part, which is located on the outer periphery of the corresponding hollow part and is electrically connected to the second electrical conduction part.

15. The power converter according to claim 13, characterized in that, The first conductive portion is flat and is at least partially disposed within the hollow portion; the second conductive portion includes two straight sections and a bent section; both straight sections extend in the first direction, and the end of one straight section near the power board is electrically connected to the first conductive portion, the end of the other straight section near the power board is electrically connected to the power board, and the bent section is electrically connected to the ends of the two straight sections away from the power board; or, The first electrically conductive part is suspended on the second surface, and the second electrically conductive part is bent relative to the first electrically conductive part.

16. The power converter according to claim 15, characterized in that, When the first electrically conductive part is suspended on the second surface, At least a portion of the electrical connector is disposed within the gap between the first electrically conductive portion and the conductive terminal; or, The conductive terminal extends out of the second surface through the corresponding hollow portion, and the side of the limiting member facing away from the conductive terminal abuts against the first electrically conductive portion.

17. The power converter according to claim 1, characterized in that, The power board has an outer wall connecting the first surface and the second surface. The hollow portion is disposed near the outer wall and simultaneously penetrates the first surface, the second surface and the outer wall.

18. The power converter according to claim 1, characterized in that, The housing has a base plate facing the first surface, and the base plate has a window. The power converter further includes: A heat dissipation device is disposed on the side of the base plate opposite to the power board, and is thermally connected to the power device through the opening.

19. An electric power system, characterized in that, The power system includes: The power converter as described in any one of claims 1 to 18.

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