POWER CONVERTER

Abstract

Power converter, with: a filter (320) connected to a battery (200); a converter (330) designed to convert a voltage of to convert battery (200) supplied via the filter (320); and a circuit busbar (331, 332) designed to connect the filter (320) and the converter (330), wherein the filter (320) comprises a passive element (321, 322) connected to the circuit busbar (331, 332), a filter housing (327) designed to contain the passive element (321, 322), and a resin component (328) that fixes the passive element (321, 322) to the filter housing (327), and the circuit busbar (331, 332) is fixed to the filter housing (327), furthermore with: a power supply busbar (311, 312) designed to connect the battery (200) and the passive element (321, 322); a capacitor unit (350) comprising a smoothing capacitor (351) connected to the battery (200) and a capacitor housing (354) designed to contain the smoothing capacitor (351); and a casing (380) designed to contain the filter (320), the converter (330), the circuit busbar (331, 332), the power supply busbar (311, 312) and the capacitor unit (350), wherein the power supply busbar (311, 312) is fixed to the capacitor housing (354), and the filter housing (327) and the capacitor housing (354) are each fixed to the casing (380).

Description

CROSS-REFERENCE TO RELATED REGISTRATION

[0001] This application is based on and claims the benefit of priority from the earlier Japanese patent application No. 2018-224367, filed on December 27, 2018, the description of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [Technical area of ​​the invention]

[0002] The disclosure relates to a power conversion device. [Related technology]

[0003] As disclosed in JP 2017-112768 A, a power conversion device is known in which a converter and a heating element are attached to a base plate. The heating element includes a filter capacitor.

[0004] DE 11 2015 004 622 T5 discloses an electrical device. This device comprises two or more electrical components that form an electrical circuit, at least one or more mechanical components that hold the two or more electrical components and are fixed to the two or more electrical components, and a position setting structure that sets the positions of the two or more electrical components relative to the one or more mechanical components, wherein the at least two or more electrical components are joined together before the one or more mechanical components are fixed to the two or more electrical components.

[0005] DE 10 2016 103 785 A1 discloses an electrical power conversion device. This device comprises semiconductor modules, a main P-bus, a main N-bus, a capacitor module, an input P-bus, and an input N-bus. The input N-bus is connected to the DC power source. The main N-bus is connected to a negative terminal of the semiconductor module to supply the DC power. A capacitor N-bus, a filter capacitor, and a smoothing capacitor within the capacitor module are formed or encased in a capacitor resin. The capacitor N-bus is connected to a negative terminal of the filter capacitor. The input N-bus has a first N-connection section connected to the capacitor N-bus and a second N-connection section connected to the main N-bus.The main N-busbar is located outside the capacitor's resin mold.

[0006] The JP 2018-160 995 A reveals an electrical power conversion system.

[0007] WO 2018 / 193 589 A1 discloses a filter module for a power conversion system.

[0008] The US 2014 / 0 301 059 A1 reveals another state-of-the-art power converter. SUMMARY

[0009] In the power conversion device disclosed in JP 2017-112768 A, if a converter and the filter capacitor (filter) vibrate independently, there is a possibility that an electrical connection fault may occur at an electrical connection section of the converter and the filter capacitor.

[0010] Therefore, it is an object of the invention to provide a power conversion device in which the occurrence of an electrical connection fault is suppressed.

[0011] The problem is solved according to the invention by a power conversion device having the features of one of the independent claims 1, 3, 6 and 9. Advantageous embodiments are defined in the dependent claims.

[0012] In this way, the passive element (321, 322) and the circuit busbar (331, 332) are fixed to the housing. Therefore, independent vibration of the passive element (321, 322) and the circuit busbar (331, 332) is suppressed. The application of stress to a connection point between the passive element (321, 322) and the circuit busbar (331, 332) is suppressed. The occurrence of an electrical connection fault at a connection point between the passive element (321, 322) and the circuit busbar (331, 332) is suppressed.

[0013] It should be noted that the reference numerals in parentheses described above merely indicate a corresponding relationship with components described in embodiments that will be described later, and do not limit any technical scope. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In the accompanying drawings: Fig. Figure 1 is a block diagram that represents a schematic design of an internal vehicle system. Fig. Figure 2 is a schematic diagram that represents a schematic design of a power conversion device. Fig. Figure 3 is a cross-sectional diagram representing a state in which a filter of the power conversion device according to a first embodiment is fixed. Fig. Figure 4 is a top view showing a state in which the power supply busbars and circuit busbars are fixed in the first embodiment. Fig. Figure 5 is a cross-sectional diagram representing a state in which a filter of a power conversion device according to a second embodiment is fixed. Fig. Figure 6 is a top view showing a state in which the power supply busbars and circuit busbars are fixed in the second embodiment. Fig. Figure 7 is a cross-sectional diagram representing a state in which a filter of a power conversion device according to a third embodiment is fixed. Fig. Figure 8 is a top view showing a state in which the power supply busbars and circuit busbars are fixed in the third embodiment. Fig. Figure 9 is a top view showing a state in which a filter of a power conversion device according to a fourth embodiment is fixed. Fig. 10 is a cross-sectional diagram representing a state in which the power supply busbars and the switching busbars are fixed in the fourth embodiment. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0015] Embodiments for implementing the disclosure are described below with reference to the drawings. In cases where components corresponding to those in a previously described embodiment are also included in subsequent embodiments, the same reference numerals are assigned, and repeated descriptions are omitted. Furthermore, in cases where only part of the design is described for a given embodiment, reference numerals from a previously described embodiment may be used for other parts of the design. Even where it is not explicitly stated that a specific combination is possible for a given embodiment, it is possible to partially combine the embodiments if no particular problem arises with the combination.Furthermore, the size of each component highlighted in the drawings is appropriate for the purpose of facilitating explanation and does not indicate an actual dimension or ratio between components. (First embodiment)<Fahrzeuginternes System>

[0016] First, an in-vehicle system 100, in which a power converter unit 300 is provided, is used. Fig. 1 described. This in-vehicle system 100 forms a system for an electric vehicle. The in-vehicle system 100 comprises a battery 200, a power converter 300, and a motor 400.

[0017] Furthermore, the vehicle's internal system 100 comprises a multitude of ECUs. These multiple ECUs transmit and receive signals to each other via bus wiring. The multiple ECUs control the electric vehicle in coordination with one another. The power drive and regeneration of the motor 400 are controlled by the multiple ECUs in accordance with the state of charge (SOC) of the battery 200. Fig. Figure 1 represents an MGECU 340 as one example of the many ECUs available. The MGECU 340 is integrated into the 300 power converter. SOC stands for state of charge. ECU stands for electronic control unit.

[0018] The Battery 200 has multiple secondary batteries. These secondary batteries form a battery stack, connected in series. The state of charge (SOC) of this battery stack is identical to the SOC of the Battery 200. The secondary batteries can be lithium-ion, nickel-hydride, organic radical, or similar. It should be noted that the Battery 200 is not limited to the aspects described above and can be designed with any secondary battery.

[0019] The power converter 300 converts power between the battery 200 and the motor 400. In the present embodiment, the power converter 300 transforms the DC power from the battery 200 down in conjunction with the power conversion. The power converter 300 supplies the down-transformed DC power to in-vehicle equipment, such as the MGECU 340, whose power consumption is lower than that of the motor 400.

[0020] Motor 400 is coupled to an output shaft of the electric vehicle, which is not shown. Rotational energy from motor 400 is transferred to a drive wheel of the electric vehicle via the output shaft. Conversely, rotational energy from the drive wheel is transferred back to motor 400 via the output shaft.

[0021] Motor 400 performs a power drive using alternating current power supplied by the power converter 300. This provides a driving force to the drive wheel. Furthermore, motor 400 performs a regeneration cycle using rotational energy transferred from the drive wheel. This generates alternating current power at motor 400. <Leistungswandelgerät>

[0022] Next, the power converter 300 will be described. As in Fig. 1 and Fig. As shown in Figure 2, the power converter 300 comprises the terminal block 310, the filter 320, the converter 330, and the MGECU 340. Furthermore, the power converter 300 comprises a first capacitor unit 350, a second capacitor unit 360, an inverter 370, and a casing 380. The terminal block 310, the filter 320, the converter 330, the MGECU 340, the first capacitor unit 350, the second capacitor unit 360, and the inverter 370 are each contained within the casing 380. These components are fixed to the casing 380 using a bolt or similar fastener.

[0023] How easy in Fig. As shown in Figure 2, the shell 380 comprises a chassis 381 and a connected wall 382, ​​which is connected to an inner wall of the chassis 381. The chassis 381 and the connected wall 382 are each formed from a metal, such as aluminum.

[0024] A flow channel to allow coolant to flow is provided on the connected wall 382. Components that generate heat particularly easily among the components of the power converter 300 are attached to this connected wall 382. In particular, the converter 330, the first condenser unit 350, the second condenser unit 360, the inverter 370, or the like are attached to the connected wall 382. It should be noted that it is also possible to use a configuration in which the MGECU 340 is attached to the connected wall 382. Other components are fixed to the chassis 381 as appropriate. Fig. 2 represents the second capacitor unit 360, which overlaps with other components.

[0025] The converter 330 converts a voltage from the battery 200, which is supplied via the filter 320. Specifically, the converter 330 steps down the DC power supplied by the battery 200 to a voltage required by in-vehicle equipment, such as the MGECU 340. The inverter 370 converts the DC power from the battery 200 into AC power. This AC power is supplied to the motor 400. Furthermore, the inverter 370 converts the AC power generated by the motor 400 into DC power. An electrical connection design for the power converter 300 is described below. <Elektrische Verbindungsgestaltung des Leistungswandelgeräts>

[0026] As in Fig. As shown in Figure 1, the terminal block 310 comprises a first power supply busbar 311 and a second power supply busbar 312. The first power supply busbar 311 is connected to a positive electrode terminal of the battery 200. The second power supply busbar 312 is connected to a negative electrode terminal of the battery 200.

[0027] The filter 320 comprises a first coil 321 and a second coil 322 as passive elements for removing electromagnetic interference. The first coil 321 is magnetically coupled to the second coil 322. These two coils form a common-mode interference filter.

[0028] The first coil 321 has two terminals. Extension busbars for extending the lengths of these two terminals are welded to them. Specifically, a first extension busbar 323 is welded to one of the two terminals of the first coil 321. A second extension busbar 324 is welded to the other of the two terminals of the first coil 321. This first extension busbar 323 and second extension busbar 324 do not necessarily have to be connected to the first coil 321.

[0029] The first power supply busbar 311 described above is mechanically and electrically connected to the first extension busbar 323. The first switching busbar 331 is mechanically and electrically connected to the second extension busbar 324.

[0030] The second coil 322 has two terminals. Extension busbars for extending the lengths of these two terminals are also welded to these two terminals. In particular, a third extension busbar 325 is welded to one of the two terminals of the second coil 322. A fourth extension busbar 326 is welded to the other of the two terminals of the second coil 322. This third extension busbar 325 and fourth extension busbar 326 need not be connected to the second coil 322.

[0031] The second power supply busbar 312 described above is mechanically and electrically connected to the third extension busbar 325. The second switching busbar 332 is mechanically and electrically connected to the fourth extension busbar 326.

[0032] The converter 330 comprises a circuit substrate in which electronic components are mounted on a printed circuit board. The first circuit busbar 331 and the second circuit busbar 332 described above are each mechanically and electrically connected to this circuit substrate.

[0033] In the electrical connection configuration described above, the battery 200 is electrically connected to the converter 330 via the first coil 321 and the second coil 322, which form the common-mode interference filter. DC power from the battery 200, from which interference has been removed by the common-mode interference filter, is supplied to the converter 330.

[0034] Although not shown, the circuit board of the converter 330 includes a first power wiring which is electrically connected to the first circuit busbar 331, a second power wiring which is electrically connected to the second circuit busbar 332, and a third power wiring which has a higher potential than that of the second power wiring.

[0035] Furthermore, the electronic element of the converter has 330 branches, each with one or more phases, connected in parallel between the third power wiring and the second power wiring. A branch with one phase has two switching elements connected in series between the third power wiring and the second power wiring.

[0036] Furthermore, the electronic element of the converter has 330 choke coils, the number of which corresponds to the number of branches. The choke coil connects a midpoint between two switching elements of the branch, which has one phase, and the first power wiring. The two switching elements of the branch are subjected to pulse-width modulation control by the ECU described above and a gate driver, not shown, which steps down the DC power supplied by battery 200.

[0037] The first capacitor unit 350 comprises a first capacitor 351, a first smoothing busbar 352, and a second smoothing busbar 353. As shown in Fig. As shown in Figure 1, the first smoothing busbar 352 is mechanically and electrically connected to the first power supply busbar 311. The second smoothing busbar 353 is mechanically and electrically connected to the second power supply busbar 312. It should be noted that the first smoothing busbar 352 and the first power supply busbar 311 can be integrated or separate. The second smoothing busbar 353 and the second power supply busbar 312 can also be integrated or separate.

[0038] The first capacitor 351 is connected between the first smoothing busbar 352 and the second smoothing busbar 353. One of the two electrodes of the first capacitor 351 is connected to the first smoothing busbar 352. The other of the two electrodes of the first capacitor 351 is connected to the second smoothing busbar 353. The first capacitor 351 is a smoothing capacitor.

[0039] The second capacitor unit 360 comprises a second capacitor 361, a third smoothing bus 362, and a fourth smoothing bus 363. The third smoothing bus 362 is mechanically and electrically connected to the first smoothing bus 352. The fourth smoothing bus 363 is mechanically and electrically connected to the second smoothing bus 353. It should be noted that the first smoothing bus 352 and the third smoothing bus 362 can be integrated or separate. The second smoothing bus 353 and the fourth smoothing bus 363 can be integrated or separate.

[0040] The second capacitor 361 is connected between the third smoothing busbar 362 and the fourth smoothing busbar 363. One of the two electrodes of the second capacitor 361 is connected to the third smoothing busbar 362. The other of the two electrodes of the second capacitor 361 is connected to the fourth smoothing busbar 363.

[0041] Then the third smoothing busbar 362 and the fourth smoothing busbar 363 are mechanically and electrically connected to the inverter 370.

[0042] With the connection configuration described above, the first capacitor 351, the second capacitor 361, and the inverter 370 are each electrically connected to the battery 200. DC power from the battery 200 is supplied to the first capacitor 351, the second capacitor 361, and the inverter 370, respectively.

[0043] It should be noted that the power converter 300 does not necessarily have to include both the first capacitor unit 350 and the second capacitor unit 360. Alternatively, it is also possible to use a design in which the power converter 300 only includes the first capacitor unit 350.

[0044] Inverter 370 has branches with three or more phases connected in parallel between the third smoothing busbar 362 and the fourth smoothing busbar 363. Each branch with three or more phases has two switching elements connected in series. One busbar is connected to the midpoint of these two switching elements. This busbar is electrically connected to a stator coil of motor 400. The switching elements are subject to pulse-width modulation control by the ECU and the gate driver described above. In this way, DC power supplied by battery 200 is converted into AC power. AC power generated by regeneration (power generation) at motor 400 is converted into DC power.

[0045] In the present embodiment, the inverter 370 comprises a heat sink for cooling the plurality of switching elements, in addition to the plurality of switching elements described above. The heat sink comprises a coolant supply line, a coolant outlet line, and a plurality of distribution lines that connect and route the coolant between the coolant supply line and the coolant outlet line. The coolant flows into these three lines. The coolant flows from the coolant supply line to the coolant outlet line via the plurality of distribution lines.

[0046] The coolant supply line and the coolant outlet line extend in the same direction. The multiple distribution lines each extend from the coolant supply line to the coolant outlet line. The multiple distribution lines are arranged separately in the directions in which the coolant supply line and the coolant outlet line extend.

[0047] A cavity is formed between two adjacent supply lines. The switching element is located in this cavity. The switching element contacts the supply lines. Heat generated at the switching element is released to the coolant via the supply lines.

[0048] It should be noted that it is possible to use an IGBT, a MOSFET, or similar device as the switching elements described above. Suitable materials for forming the switching elements include semiconductors such as silicon and wide-bandgap semiconductors such as silicon carbide. <Mechanische Verbindungsgestaltung des Leistungswandelgeräts>

[0049] Next, a mechanical connection design of the power converter 300 is described. The terminal block 310 comprises a busbar housing 313, which contains the first power supply busbar 311 and the second power supply busbar 312 described above. The busbar housing 313 is formed with an insulating resin material. The busbar housing 313 is fixed to the chassis 381 by a bolt or the like.

[0050] As in Fig. 3 and Fig. As shown in Figure 4, the filter 320 comprises a filter housing 327 containing the first coil 321 and second coil 322 described above. The filter housing 327 is formed with an insulating resin material. As shown in Fig. As shown in Figure 3, the filter housing 327 is fixed to the chassis 381 with a bolt or the like.

[0051] As in Fig. 3 and Fig. As shown in Figure 4, a second concave section 327a, which is locally concave, is formed on the filter housing 327. The first coil 321 and the second coil 322 are each provided in this second concave section 327a. The first coil 321 and the second coil 322 are each fixed to the filter housing 327 within the second concave section 327a by an insulating resin component 328. At least a portion of a section, excluding a section in which the first coil 321 and the second coil 322 are welded to the respective busbars, is embedded in the resin component 328. The first to fourth extension busbars 323-326, which extend the respective connections of the first coil 321 and the second coil 322, are each located outside the resin component 328.

[0052] As in Fig. As shown in Figure 4, the first extension busbar 323 is mechanically and electrically connected to the first power supply busbar 311 by a first bolt 391. Accordingly, the first extension busbar 323 and the first power supply busbar 311 are mechanically connected to (fixed to) the first capacitor housing 354 by the first bolt 391.

[0053] The second extension busbar 324 is mechanically and electrically connected to the first switching busbar 331 by a second bolt 392. Accordingly, the second extension busbar 324 and the first switching busbar 331 are fixed to the filter housing 327 by the second bolt 392.

[0054] Similarly, the third extension busbar 325 is mechanically and electrically connected to the second power supply busbar 312 by a third bolt 393. Accordingly, the third extension busbar 325 and the second power supply busbar 312 are fixed to the first capacitor housing 354 by the third bolt 393.

[0055] The fourth extension busbar 326 is mechanically and electrically connected to the second switching busbar 332 by a fourth bolt 394. Accordingly, the fourth extension busbar 326 and the second switching busbar 332 are fixed to the filter housing 327 by the fourth bolt 394. Fig. 1. The first to fourth bolts 391-394 are each indicated with white circles.

[0056] It should be noted that it is also possible to use a design in which the extension busbar is partially mechanically and electrically connected to the power supply busbar by welding or similar means, even though the extension busbar is connected to the power supply busbar by a bolt. In this case, the extension busbar does not need to be electrically connected to the power supply busbar by a bolt.

[0057] Similarly, it is also possible to use a design in which the extension busbar is partially mechanically and electrically connected to the circuit busbar by welding or similar means, even though the extension busbar is connected to the circuit busbar by a bolt. In this case, the extension busbar does not need to be electrically connected to the circuit busbar by a bolt.

[0058] The first capacitor unit 350, which was in Fig. As shown in Figure 2, the first capacitor housing 354 comprises the first capacitor 351, the first smoothing busbar 352, and the second smoothing busbar 353, as described above. The first capacitor housing 354 is formed from an insulating resin material. A portion of both the first smoothing busbar 352 and the second smoothing busbar 353 is inserted into the first capacitor housing 354, for example, by injection molding. The first capacitor housing 354 is then fixed to the connected wall 382 with a bolt or the like. Furthermore, as described above, in the present embodiment, the first extension busbar 323 and the first power supply busbar 311, as well as the third extension busbar 325 and the second power supply busbar 312, are each attached to the first capacitor housing 354 with bolts.

[0059] The second capacitor unit 360, which is in Fig. Figure 2 also includes the second capacitor housing 364, which is formed with an insulating resin material in the same way as the first capacitor unit 350. In the present embodiment, as schematically shown in Figure 2, the second capacitor housing 364 is formed with an insulating resin material in the same manner as the first capacitor unit 350. Fig. Figure 2 shows the second capacitor unit being 360 larger than the first capacitor unit, which is 350 larger.

[0060] The second capacitor unit 360 is due to the circuit design, which is in Fig. As shown in Figure 1, the first capacitor unit 350 is probably located further away from the terminal block 310 than the first capacitor unit 350. Therefore, the first extension busbar 323 and the third extension busbar 325 are not bolted to the second capacitor housing 364, but are bolted to the first capacitor housing 354. <Wirkungen im Betrieb>

[0061] The effects of the operation of the power converter 300 are described next. As described above, the first coil 321 and the second coil 322 are fixed to the filter housing 327. Furthermore, the first busbar 331 and the second busbar 332, which are each connected to the first coil 321 and the second coil 322 respectively, are fixed to the filter housing 327.

[0062] Therefore, independent vibration of the first coil 321 and the first busbar 331 due to an external force, such as vehicle vibration, is suppressed. Similarly, independent vibration of the second coil 322 and the second busbar 332 is suppressed. In this way, the application of voltage to both a connection section between the first coil 321 and the first busbar 331, and a connection section between the second coil 322 and the second busbar 332, is suppressed. The occurrence of electrical connection faults at these connection sections of the coils and the busbars is thus suppressed.

[0063] As described above, the first coil 321 and the second coil 322 are fixed to the filter housing 327. The first power supply busbar 311, which is connected to the first coil 321, and the second power supply busbar 312, which is connected to the second coil 322, are each fixed to the first capacitor housing 354. The filter housing 327 and the first capacitor housing 354 are each fixed to the casing 380.

[0064] In this way, the filter housing 327 is indirectly coupled to the first capacitor housing 354 via the casing 380. Therefore, independent vibration of the first coil 321 and the first power supply busbar 311 due to an external force, such as vehicle vibration, is suppressed. Similarly, independent vibration of the second coil 322 and the second power supply busbar 312 is suppressed. This prevents the application of voltage to any connection section between the first coil 321 and the first power supply busbar 311, as well as to any connection section between the second coil 322 and the second power supply busbar 312. The occurrence of electrical connection faults at these connection sections of the coils and the power supply busbars is thus prevented.

[0065] It should be noted that, in order to suppress independent vibration of the coils and the power supply busbars more effectively, it is also possible to employ a design in which the filter housing 327 is directly coupled to the first capacitor housing 354 by fitting them together. The coupling method between the filter housing 327 and the first capacitor housing 354 is not particularly limited.

[0066] In the present embodiment, an example has been described in which the first power supply busbar 311 and the second power supply busbar 312 are each fixed to the first capacitor housing 354. However, it is also possible to use a design in which the first power supply busbar 311 and the second power supply busbar 312 are each fixed to the filter housing 327. It is also possible to use a design in which the first power supply busbar 311 and the second power supply busbar 312 are each fixed to the busbar housing 313.

[0067] As described above, the converter 330 is a circuit substrate in which electronic components are mounted on a printed circuit board. The filter 320 is not mounted on this circuit board. Therefore, it is possible to determine the size of the passive element of the filter 320 regardless of the size and stiffness of the circuit board. (Second embodiment)

[0068] A second embodiment will next be described using Fig. 5 and Fig. Section 6 describes. A power conversion device according to each embodiment described below has much in common with the power conversion device in the embodiment described above. Therefore, a description of common points is omitted below, and various points are described in detail. Furthermore, in the following description, the same reference numerals are assigned to the same components as those indicated in the embodiment described above.

[0069] In the first embodiment, an example was described in which the filter 320 comprises the filter housing 327 and the first coil 321 and the second coil 322 are contained in the filter housing 327. In contrast, in the present embodiment, the first coil 321 and the second coil 322 are contained in the busbar housing 313.

[0070] As in Fig. 5 and Fig. As shown in Figure 6, a first concave section 313a, which is locally concave, is formed on the busbar housing 313. The first coil 321 and the second coil 322 are each provided in this first concave section 313a. The first coil 321 and the second coil 322 are each fixed to the busbar housing 313 within the first concave section 313a by the resin component 328.

[0071] As in Fig. As shown in Figure 6, the first extension busbar 323 and the first power supply busbar 311 are mechanically connected to (fixed to) the busbar housing 313 by the first bolt 391. The second extension busbar 324 and the first switching busbar 331 are fixed to the busbar housing 313 by the second bolt 392.

[0072] Similarly, the third extension busbar 325 and the second power supply busbar 312 are fixed to the busbar housing 313 with the third bolt 393. The fourth extension busbar 326 and the second switching busbar 332 are fixed to the busbar housing 313 with the fourth bolt 394.

[0073] As described above, the first coil 321 and the second coil 322 are each fixed to the busbar housing 313. Furthermore, the first switching busbar 331 and the first power supply busbar 311, which are connected to the first coil 321, and the second switching busbar 332 and the second power supply busbar 312, which are connected to the second coil 322, are each fixed to the busbar housing 313.

[0074] Therefore, independent vibration of the first coil 321, the first circuit bus 331, and the first power supply bus 311 due to an external force, such as vehicle vibration, is suppressed. Similarly, independent vibration of the second coil 322, the second circuit bus 332, and the second power supply bus 312 is suppressed. In this way, the application of voltage to both a connection section of the first coil 321 and the first circuit bus 331, and a connection section of the first coil 321 and the first power supply bus 311, is suppressed. The application of voltage to both a connection section of the second coil 322 and the second circuit bus 332, and a connection section of the second coil 322 and the second power supply bus 312, is also suppressed.As a result, the occurrence of an electrical connection fault at both the connection section of the coil and the circuit busbar and the connection section of the coil and the power supply busbar is suppressed.

[0075] It should be noted that the power converter 300 according to the present embodiment comprises components that are equivalent to the components of the power converter 300 described in the first embodiment. Therefore, it is unnecessary to state that equivalent effects are provided in operation. The same applies to the respective embodiments and modified examples described below. (Third embodiment)

[0076] A third embodiment will next be described using Fig. 7 and Fig. 8 described.

[0077] In the second embodiment, an example was described in which the first coil 321 and the second coil 322 are contained in the busbar housing 313. In contrast, in the present embodiment, the first coil 321 and the second coil 322 are contained in the first capacitor housing 354.

[0078] As in Fig. 7 and Fig. As shown in Figure 8, a third concave section 354a, which is locally concave, is formed on the first capacitor housing 354. The first coil 321 and the second coil 322 are each provided in this third concave section 354a. The first coil 321 and the second coil 322 are each fixed to the first capacitor housing 354 within the third concave section 354a by an insulating resin component 328.

[0079] As in Fig. As shown in Figure 8, the first extension busbar 323 and the first power supply busbar 311 are mechanically connected to (fixed to) the first capacitor housing 354 by the first bolt 391. The second extension busbar 324 and the first circuit busbar 331 are fixed to the first capacitor housing 354 by the second bolt 392.

[0080] In this way, the third extension busbar 325 and the second power supply busbar 312 are fixed to the first capacitor housing 354 with the third bolt 393. The fourth extension busbar 326 and the second circuit busbar 332 are fixed to the first capacitor housing 354 with the fourth bolt 394.

[0081] As described above, the first coil 321 and the second coil 322 are each fixed to the first capacitor housing 354. Furthermore, the first circuit bus 331 and the first power supply bus 311, which are connected to the first coil 321, and the second circuit bus 332 and the second power supply bus 312, which are connected to the second coil 322, are each fixed to the first capacitor housing 354.

[0082] Therefore, in the same way as in the second embodiment of the power conversion device 300, the occurrence of an electrical connection fault at both the connection section of the coil and the circuit busbar and the connection section of the coil and the power supply busbar is suppressed in the power conversion device 300 in the present embodiment. (Fourth embodiment)

[0083] A fourth embodiment will next be described using Fig. 9 and Fig. 10 described.

[0084] In the third embodiment, an example was described in which the first coil 321 and the second coil 322 are contained in the first capacitor housing 354. In contrast, in the present embodiment, the first coil 321 and the second coil 322 are contained in the filter housing 327. The filter housing 327 is fixed to the first capacitor housing 354.

[0085] In the same manner as in the first embodiment, the first coil 321 and the second coil 322 are provided in the second concave section 327a of the filter housing 327. The first coil 321 and the second coil 322 are fixed to the filter housing 327 within the second concave section 327a by the resin component 328.

[0086] As in Fig. 9 and Fig.As shown in Figure 10, the filter housing 327 is fixed to the first capacitor housing 354 by a bolt or the like. Furthermore, the first extension busbar 323 and the first power supply busbar 311 are mechanically connected to (fixed to) the first capacitor housing 354 by the first bolt 391. The second extension busbar 324 and the first circuit busbar 331 are fixed to the first capacitor housing 354 by the second bolt 392.

[0087] The third extension busbar 325 and the second power supply busbar 312 are fixed to the first capacitor housing 354 by the third bolt 393. The fourth extension busbar 326 and the second circuit busbar 332 are fixed to the first capacitor housing 354 by the fourth bolt 394.

[0088] As described above, the filter housing 327, which contains the first coil 321 and the second coil 322, is fixed to the first capacitor housing 354. Furthermore, the first circuit bus 331 and the first power supply bus 311, as well as the second circuit bus 332 and the second power supply bus 312, are each fixed to the first capacitor housing 354.

[0089] Therefore, for example, in the same way as in the third embodiment of the power conversion device 300, the occurrence of an electrical connection fault at both the connection section of the coil and the circuit busbar and the connection section of the coil and the power supply busbar is suppressed in the present embodiment of the power conversion device 300.

[0090] In the present embodiment, an example has been described in which the filter housing 327, the first power supply busbar 311, the second power supply busbar 312, the first circuit busbar 331, and the second circuit busbar 332 are each fixed to the first capacitor housing 354. However, it is also possible to use a design in which the filter housing 327, the first power supply busbar 311, the second power supply busbar 312, the first circuit busbar 331, and the second circuit busbar 332 are each fixed to the busbar housing 313.

[0091] Although preferred embodiments of the disclosure have been described above, the disclosure is not limited to the embodiments described above and can be implemented, although various modifications are made within a scope that does not deviate from the core of the disclosure. (Further modified examples)

[0092] Examples where different types of components of the power converter 300 are fastened with bolts have been described in the respective embodiments. The mounting directions for these multiple bolts are the same. In particular, the direction in which the inverter 370 is attached to the casing 380 with a bolt is the same as the mounting directions for the respective first to fourth bolts 391 to 394. Since the mounting directions are thus made the same, the work of fastening with bolts is simplified.

[0093] Examples where the power converter 300 is included in the vehicle's internal system 100 for an electric vehicle have been described in the respective embodiments. However, the application of the power converter 300 is not specifically limited to the examples described above. For example, it is also possible to use a configuration where the power converter 300 is included in a hybrid system comprising a motor and an internal combustion engine. Furthermore, the power converter 300 can, for example, be provided in any device or equipment that is not a vehicle.

[0094] A configuration in which the power converter 300 is connected to one motor 400 has been described in the respective embodiments. However, it is also possible to use a configuration in which the power converter 300 is connected to two motors 400. In this case, the power converter 300 comprises two inverters 370.

[0095] A power conversion device comprises a filter 320 connected to a battery, a converter designed to convert a voltage supplied by the battery via the filter, and circuit busbars 331 and 332 designed to connect the filter and the converter. The filter includes coils 321 and 322 connected to the circuit busbars, a filter housing 327 designed to contain the coils, and a resin component 328 that fixes the coils to the filter housing. The circuit busbars are fixed to the filter housing.

Claims

[1] Power converter, with: a filter (320) connected to a battery (200); a converter (330) designed to convert a voltage of to convert battery (200) supplied via the filter (320); and a circuit busbar (331, 332) designed to connect the filter (320) and the converter (330), wherein the filter (320) comprises a passive element (321, 322) connected to the circuit busbar (331, 332), a filter housing (327) designed to contain the passive element (321, 322), and a resin component (328) that fixes the passive element (321, 322) to the filter housing (327), and the circuit busbar (331, 332) is fixed to the filter housing (327), furthermore with: a power supply busbar (311, 312) designed to connect the battery (200) and the passive element (321, 322); a capacitor unit (350) comprising a smoothing capacitor (351) connected to the battery (200) and a capacitor housing (354) designed to contain the smoothing capacitor (351); and a casing (380) designed to contain the filter (320), the converter (330), the circuit busbar (331, 332), the power supply busbar (311, 312) and the capacitor unit (350), wherein the power supply busbar (311, 312) is fixed to the capacitor housing (354), and the filter housing (327) and the capacitor housing (354) are each fixed to the casing (380). [2] Power conversion device according to claim 1, wherein a concave section (327a), which is locally concave, is formed on the filter housing (327), the passive element (321, 322) is provided in the concave section, and a part of the passive element (321, 322) is embedded in the resin component (328). [3] Power converter, with: a filter (320) connected to a battery (200); a converter (330) designed to convert a voltage from the battery (200) supplied via the filter (320); a terminal block (310) comprising a power supply busbar (311, 312) designed to connect the battery (200) and the filter (320), and a busbar housing (313) designed to contain the power supply busbar (311, 312); and a circuit busbar (331, 332) designed to connect the filter (320) and the converter (330), wherein the filter (320) comprises a passive element (321, 322) connected to both the power supply busbar (311, 312) and the switching busbar (331, 332), and a resin component (328) that fixes the passive element (321, 322) to the busbar housing (313), and the circuit busbar (331, 332) is fixed to the busbar housing (313). [4] Power conversion device according to claim 3, wherein the power supply busbar (311, 312) is fixed to the busbar housing (313). [5] Power conversion device according to claim 4, wherein a concave section (313a), which is locally concave, is formed on the busbar housing (313), the passive element (321, 322) is provided in the concave section (313a), and a part of the passive element (321, 322) is embedded in the resin component (328). [6] Power converter, with: a filter (320) connected to a battery (200); a converter (330) designed to convert a voltage from the battery (200) supplied via the filter (320); a capacitor unit (350) comprising a smoothing capacitor (351) connected to the battery (200) and a capacitor housing (354) designed to contain the smoothing capacitor (351); and a circuit busbar (331, 332) designed to connect the filter (320) and the converter (330), wherein the filter (320) comprises a passive element (321, 322) connected to the circuit busbar (331, 332) and a resin component (328) that fixes the passive element (321, 322) to the capacitor housing (354), and the circuit busbar (331, 332) is fixed to the capacitor housing (354), furthermore with a casing (380) designed to contain the filter (320), the converter (330), the circuit busbar (331, 332) as well as the capacitor unit (350), wherein the capacitor housing (354) is fixed to the casing (380). [7] Power conversion device according to claim 6, comprising: a power supply busbar (311, 312) designed to connect the battery (200) and the passive element (321, 322), wherein the power supply busbar (311, 312) is fixed to the capacitor housing (354). [8] Power conversion device according to claim 6 or 7, wherein a concave section (354a), which is locally concave, is formed on the capacitor housing (354), the passive element (321, 322) is provided in the concave section (354a), and a part of the passive element (321, 322) is embedded in the resin component (328). [9] Power converter, with: a filter (320) connected to a battery (200); a converter (330) designed to convert a voltage from the battery (200) supplied via the filter (320); a terminal block (310) comprising a power supply busbar (311, 312) designed to connect the battery (200) and the filter (320), and a busbar housing (313) designed to contain the power supply busbar (311, 312); a circuit busbar (331, 332) designed to connect the filter (320) and the converter (330); and a capacitor unit (350) comprising a smoothing capacitor (351) connected to the battery (200) and a capacitor housing (354) designed to contain the smoothing capacitor (351), wherein the filter (320) comprises a passive element (321, 322) connected to both the power supply busbar (311, 312) and the circuit busbar (331, 332), a filter housing (327) designed to contain the passive element (321, 322), and a resin component (328) that fixes the passive element (321, 322) to the filter housing (327), and both the filter housing (327) and the circuit busbar (331, 332) are fixed to the busbar housing (313) or the capacitor housing (354). [10] Power conversion device according to claim 9, wherein the power supply busbar (311, 312) together with both the filter housing (327) and the circuit busbar (331, 332) is fixed to the busbar housing (313) or the capacitor housing (354). [11] Power conversion device according to claim 9 or 10, wherein a concave section (327a), which is locally concave, is formed on the filter housing (327), the passive element (321, 322) is provided in the concave section (327a), and a part of the passive element (321, 322) is embedded in the resin component (328). [12] Power conversion device according to any one of claims 1 to 11, where filter (320) is a common-mode noise filter, and the passive element (321, 322) comprises a first coil (321) and a second coil (322) which are magnetically coupled.

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