CONVERTER AND METHOD FOR MANUFACTURING A CONVERTER

Abstract

A converter (1) and a method for manufacturing a converter (1) are disclosed. A capacitor (6) is housed in a casing (2) of the converter (1). The capacitor (6) rests with its underside (8) against a stop (9) of a lower casing part (4). At least one elastic element (20) is provided on the top (7) of the capacitor (6) and acts as a clamping element to press the capacitor (6) directly and / or indirectly against the stop (9) of the lower casing part (4) with a clamping force (100).

Description

[0001] The invention relates to a converter. The invention particularly relates to a converter enclosed by a housing comprising a lower housing part and an upper housing part and enclosing at least one circuit board with at least one capacitor.

[0002] Furthermore, the invention relates to a method for producing a converter. • State of the art

[0003] DE 10 2020 131 009 A1 relates to a converter, in particular a multi-phase three-phase converter, with a DC link and a power module housed on a common circuit board. The circuit board is equipped with capacitors, which thus take up space on the circuit board.

[0004] DE 20 2012 103 448 U1 concerns a modular converter. Each module comprises a capacitor unit consisting of several capacitors.

[0005] EP 0 994 557 B1 discloses a compact electronic circuit arrangement in the form of a converter for high requirements with low-inductance capacitors integrated in the intermediate circuit structure. A flat intermediate circuit busbar connects the capacitors. The entire converter arrangement is housed in a housing on the heat sink below the flat intermediate circuit busbar. As is well known, the capacitor is one of the heaviest components in a converter. The capacitor is usually screwed to a housing component. Due to the limited space available, the required screwing points are difficult to implement. The screwing points also take up space that could be used for more capacity (a larger capacitor). The screwing points are usually located on the capacitor to secure it to a solid surface or housing component. • Brief description of the invention

[0006] It is therefore an object of the invention to provide a converter which realizes a simple and secure fastening of the capacitor in the housing of the converter and thus minimizes the movement of the capacitor in the housing.

[0007] The above object is achieved by a converter comprising the features of claim 1.

[0008] A further object of the invention is to provide a method for manufacturing a converter which realizes a simple and secure fastening of the capacitor in the housing of the converter and thus minimizes the movement of the capacitor in the housing.

[0009] This object is achieved by a method comprising the features of claim 8.

[0010] According to one embodiment of the invention, a converter is enclosed by a housing consisting of a lower housing part and an upper housing part. At least one circuit board with at least one capacitor is enclosed in the housing. The at least one capacitor rests with a bottom side against a stop of the lower housing part. At least one elastic element is provided on an upper side of the capacitor, which, in operative connection with a clamping partner, presses the capacitor directly and / or indirectly against the stop of the lower housing part.

[0011] The invention has the advantage that screw points for placing and positioning the capacitor in the converter housing can be omitted, while still reducing the movement of the capacitor within the housing without screw points. This ultimately saves space in the housing that could be used for other components.

[0012] According to one embodiment of the invention, the at least one elastic element also acts as a clamping partner on the top side of the capacitor. The clamping partner presses the capacitor directly against the stop or against a compensating mass of the lower housing part with a clamping force. In a preferred embodiment, the at least one elastic element is designed as a leaf spring.

[0013] According to a further embodiment of the invention, a compensating mass is provided on the stop of the lower housing part. The advantage of the compensating mass is that it compensates for flatness tolerances of the lower housing part and the underside of the capacitor. In addition, it provides a sufficient thermal contact surface for heat dissipation into the cooling channel of the lower housing part.

[0014] According to an advantageous embodiment, the leveling compound is a gap pad or gap filler. The advantage of a gap pad or gap filler is that it ensures sufficient heat transfer to the cooling channel.

[0015] According to a further advantageous embodiment of the invention, the clamping partner for the at least one elastic element is the upper housing part, which compresses and / or deforms the elastic element on the upper side of the capacitor from above. The lower housing part can also be regarded as a clamping partner, since it presses passively against the at least one elastic element from below. As a result, the capacitor is pressed with a clamping force against the stop of the lower housing part or against the compensating mass on the stop of the lower housing part. The at least one elastic element on the upper side of the capacitor can be, for example, a gap pad, a gap filler, a silicone mat, a leaf spring or a disc spring. It is also conceivable for different types of elastic elements to be attached to the upper side of the capacitor.For example, the different types of elastic elements are evenly distributed on the top of the capacitor, resulting in a homogeneous pressure force.

[0016] An embodiment of the method according to the invention for producing a converter which is surrounded by a housing comprising a lower housing part and an upper housing part and encloses at least one circuit board with at least one capacitor, is characterized by the following steps: • that at least one capacitor is positioned with a bottom side on a stop of the lower housing part or on a balancing mass on the stop; and • that at least one elastic element is placed on an upper side of the capacitor, wherein the at least one elastic element, in operative connection with a clamping partner, presses the capacitor indirectly and / or directly against the stop or the compensating mass on the stop of the lower housing part.

[0017] According to an advantageous embodiment of the method, the upper housing part serves as the clamping partner. Attaching the upper housing part, which serves as the clamping partner, to the lower housing part causes the at least one elastic element on the top side of the capacitor to be compressed or deformed. The resulting clamping force presses the capacitor indirectly against the stop, or the stop provided with the compensating mass, of the lower housing part. • Definitions:• Gap filler:

[0018] Gap fillers are thermally conductive, liquid-applied materials. These thermally conductive gap fillers are often applied by metered mixing of a two-component system using a dispensing system. Silicone-based, polyurethane-based, or acrylate-based systems are often used as the base.

[0019] Once these materials are applied, the gap filler cures. After curing, the material forms a strong yet compliant interface that dissipates heat away from the electronic components, resulting in longer lifespans and higher performance. Gap fillers are often used as a replacement for thermal pads because they achieve lower thermal impedance and offer greater design flexibility. Gap fillers are also well-suited for high-volume production of electronic components such as batteries, inverters / converters, motors, and power electronics. • Gap pad:

[0020] Gap pads are soft, elastic, relatively thick mats with heat-conducting properties. Their thickness and elasticity allow them to compensate for height differences between components. Silicone-based, polyurethane-based, or acrylate-based systems are often used as a base material.

[0021] The low self-adhesive strength of the gap pads, which can be achieved through special adjustments, allows for simplified pre-assembly in many cases. Where stronger adhesive strength is required, self-adhesive versions of the gap pads can also be used. • Short description of the drawings

[0022] The invention is explained in more detail below with reference to the accompanying drawings. Fig. 1 shows a sectional view of an inverter according to an embodiment of the invention for mounting a capacitor in a housing of the inverter. Fig. 2 shows a sectional view of a converter according to another embodiment of the invention for mounting a capacitor in a housing of the converter. Fig. 3 shows a sectional view of an inverter according to yet another embodiment of the invention for mounting a capacitor in a housing of the inverter. Fig. 4 shows schematically the positioning of the capacitor in the housing of the converter according to an embodiment of the method according to the invention. Fig. 5 shows schematically the clamping of the capacitor in the housing of the converter according to an embodiment of the method according to the invention. • Detailed description of the embodiments and drawings

[0023] Fig. 1 and Fig. 2 each show a sectional view of an embodiment of a converter 1, which comprises a housing 2 consisting of an upper housing part 3 and a lower housing part 4. The housing 2 encloses at least one capacitor 6 and at least one circuit board 14 with, according to one possible embodiment, power semiconductors (power electronics; not shown). The at least one capacitor 6 is connected to the circuit board 14 via an electrical connection 15. The housing 2 provides an installation space 5 for the electronic and mechanical components of the converter 1. The upper housing part 3 and the lower housing part 4 are connected to one another, for example, via a connecting means 16, which can be a screw connection, for example. The lower housing part 4 has a cooling channel 11, with which the heat, for example, from the capacitor 6 inside the housing 2 can be dissipated.For this purpose, the capacitor 6 rests with its underside 8 on a stop 9 of the lower housing part 4.

[0024] At the Fig. 1, the capacitor 6 rests with its underside 8 directly on the stop 9 of the lower housing part 4. In this case, heat is transferred from the underside 8 of the capacitor 6 to the cooling channel 11. At least one elastic element 20 is applied to the top side 7 of the capacitor 6, which is designed, for example, as a gap pad, gap filler, silicone mat, leaf spring, disc spring, etc. In the embodiment described here, the at least one elastic element 20 is designed as a gap pad and / or gap filler, but this should not be construed as a limitation of the invention. When using one or more gap pads and / or gap fillers on the top side 7 of the capacitor 6, heat can also be dissipated from the capacitor 6 to the upper housing part 4.After the one or more gap pads and / or gap fillers have been applied to the top side 7 of the capacitor 6, the upper housing part 3 is placed onto the lower housing part 4, wherein the upper housing part 3 represents a clamping partner and compresses the one or more gap pads and / or gap fillers, so that a clamping force 100 is built up, which presses the underside 8 of the capacitor 6 against the stop 9 of the lower housing part 4. For this purpose, the top side 7 of the capacitor 6 has a distance 17 from the upper housing part 4, which is smaller than the thickness of the one or more gap pads and / or gap fillers, in order to bring about the compression of the gap pad(s) and / or gap filler when the upper housing part 4 is applied.

[0025] At the Fig. In the embodiment of the converter 1 shown in Figure 2, the capacitor 6 rests at least partially with its underside 8 on a compensating mass 10 to compensate for tolerances in the lower housing part 4. It is also conceivable for the compensating mass 10 to cover the entire stop 9 of the lower housing part 4, so that the underside 8 of the capacitor 6 rests completely on the compensating mass 10. The compensating mass 10 can be designed as a gap pad, gap filler, etc., which compensates for the flatness tolerances of the underside 8 of the capacitor 6. On the underside 8 of the capacitor 6, a gap pad or gap filler ensures the heat transfer from the capacitor 6 to the cooling channel 11. In the embodiment shown here, the at least one elastic element 20 on the top side 7 of the capacitor 6 is a disc spring, although this should not be construed as a limitation of the invention.After the at least one disc spring 20 has been applied to the upper side 7 of the capacitor 6, the upper housing part 3 is placed on the lower housing part 4, wherein the upper housing part 3 represents a clamping partner and compresses and / or deforms the at least one disc spring 20, so that in this embodiment too, a clamping force 100 is built up which presses the underside 8 of the capacitor 6 against the stop 9 or against the compensating mass 10 of the lower housing part 4. For this purpose, too, the upper side 7 of the capacitor 6 has a distance 17 from the upper housing part 4, which is smaller than a vertical extension of the at least one disc spring 20 in order to be able to effect the deformation of the at least one disc spring 20 when the upper housing part 4 is applied.

[0026] Fig. 3 shows a converter 1 according to yet another embodiment of the invention for mounting a capacitor 6 in a housing 2 of the converter 1. The capacitor 6 is already attached to the lower housing part 4, but the upper housing part 3 is still missing. In this embodiment, the at least one elastic element 20 is a leaf spring that acts on the upper side 7 of the capacitor 6. The leaf spring 20 can exert a clamping force 100 on its own, i.e., without the attached upper housing part 3 as an additional clamping partner. The clamping force 100 of the leaf spring 20 is sufficiently high to press the capacitor 6 against the stop 9 or against the compensating mass 10 of the lower housing part 4. Of course, in a further embodiment, the clamping force 100 exerted by the leaf spring 20 can be additionally secured and / or reinforced by the upper housing part 3.

[0027] Again Fig. 4, in one embodiment of the method according to the invention, the production of a converter 1 is carried out such that the capacitor 6 is positioned on a stop 9 of the lower housing part 4. In the embodiment described here, a compensating mass 10 in the form of a gap pad or a gap filler is applied to the stop 9 of the lower housing part 4. As already mentioned above, the provision of a compensating mass 10 depends on the flatness tolerances of the stop 9 and the underside 8 of the capacitor 6. The capacitor 6 is placed with its underside 8 on the stop 9 or the compensating mass 10. The compensating mass 10 ensures the heat transfer to the cooling channel 11 of the lower housing part 4 on the underside 8 of the capacitor 6.

[0028] In the following (after the steps according to Fig. 4) will be like the Fig.5, at least one elastic element 20 is placed on the top side 7 of the capacitor 6. In the embodiment shown here, the elastic element 20 is a gap pad or a gap filler without limiting the invention. The upper housing part 3, which represents a clamping partner for the at least one elastic element 20, is then placed on the lower housing part 4 and connected to it. The at least one elastic element 20 on the top side 7 of the capacitor 6 is compressed by the placed upper housing part 3. As a result of the compression of the at least one elastic element 20, the capacitor 6 is indirectly pressed with a clamping force 100 against the stop 9 or the compensating mass 10 of the lower housing part 4. In the lower housing part 4, the heat transfer to the cooling channel 11 is ensured by the at least one elastic element 20 (gap pad or gap filler).In the embodiment shown here, heat can also be dissipated on the upper side 7 of the capacitor 6 to the lower housing part 4 with the cooling channel 11 by means of the at least one elastic element 20 (gap pad or gap filler).

[0029] It is believed that the present disclosure and many of the advantages recited therein will be understood from the foregoing description. It will be apparent that various changes in form, construction, and arrangement and combination of components may be made without departing from the disclosed subject matter. The form described is merely illustrative, and it is the intent of the appended claims to encompass and embrace such changes. Accordingly, the scope of the invention should be limited only by the appended claims. List of reference symbols 1 inverter 2 housings 3 upper housing part 4 lower housing part 5 Installation space 6 Capacitor 7 Top of the capacitor 8 Bottom of the capacitor 9 stop 10 leveling compound 11 Cooling channel 14 circuit boards 15 electrical connection 16 connecting devices 17 Distance 20 elastic element 100 clamping force QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2020 131 009 A1

[0003] DE 20 2012 103 448 U1

[0004] EP 0 994 557 B1

[0005]

Claims

[1] Converter (1) which is surrounded by a housing (2) comprising a lower housing part (4) and an upper housing part (3) and which encloses at least one circuit board (14) with at least one capacitor (6), characterized by , that the at least one capacitor (6) rests with a bottom side (8) against a stop (9) of the lower housing part (4); and at least one elastic element (20) is provided on an upper side (7) of the capacitor (6), which, in operative connection with a clamping partner, presses the capacitor (6) indirectly and / or directly against the stop (9) of the lower housing part (4). [2] Converter (1) according to claim 1, wherein the at least one elastic element (20) acts on the upper side (7) of the capacitor (6) as a clamping partner and presses the capacitor (6) directly with a clamping force (100) against the stop (9) of the lower housing part (4). [3] Converter (1) according to claim 2, wherein the at least one elastic element (20) is a leaf spring. [4] Converter (1) according to one of the preceding claims, wherein the lower housing part (4) carries a compensating mass (10) to compensate for flatness tolerances of the lower housing part (4) and the underside (8) of the capacitor (6). [5] Converter (1) according to one of the preceding claims, wherein the compensating mass (10) is a gap pad or a gap filler. [6] Converter (1) according to claim 1, wherein the clamping partner is the upper housing part (3), which compresses or deforms the elastic element (20) on the upper side (7) of the capacitor (6) and presses the capacitor (6) indirectly with a clamping force (100) against the stop (9) of the lower housing part (4). [7] Converter (1) according to claim 6, wherein the at least one elastic element (20) is a gap pad, a gap filler, a silicone mat, a leaf spring or a disc spring. [8] Method for producing a converter (1) which is surrounded by a housing (2) comprising a lower housing part (4) and an upper housing part (3) and enclosing at least one circuit board (14) with at least one capacitor (6), comprising the following steps: Positioning the at least one capacitor (6) with a bottom side (8) on a stop (9) or on a balancing mass (10) on the stop (9) of the lower housing part (4); and Placing at least one elastic element (20) on an upper side (7) of the capacitor (6), which, in operative connection with a clamping partner, presses the capacitor (6) indirectly and / or directly against the stop (9) or the compensating mass (10) on the stop (9) of the lower housing part (4). [9] Method according to claim 8, wherein the at least one elastic element (20) is itself the clamping partner and thus the capacitor (6) is pressed directly with a clamping force (100) against the stop (9) of the lower housing part (4). [10] Method according to claim 8, wherein the upper housing part (3) is the clamping partner which compresses or deforms the at least one elastic element (20) on the upper side (7) of the capacitor (6) and presses the capacitor (6) indirectly with a clamping force (100) against the stop (9) of the lower housing part (4).

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