FILTER CIRCUIT DEVICE AND POWER CONVERTER COMPREHENSIVE FILTER CIRCUIT DEVICE

Abstract

Filter circuit device, comprising: a first core element (814) designed to form a first through hole (813); a second core element (816) designed to form a second through hole (815); a first ladder (811) designed to guide through the first through hole (813) and the second through hole (815); a second conductor (812) designed to guide through the first through hole (813) and the second through hole (815); a capacitor; a first terminal (817) designed for electrically connecting the first conductor (811) to the capacitor; and a second terminal (818) designed for electrically connecting the second conductor (812) to the capacitor, where the first ladder (811) from the first through hole (813) to the second through hole (815) and the second ladder (812) from the first through hole (813) to the second through hole (815) have an opposite part (820) between the first ladder (811) and the second ladder (812), the first terminal (817) presses against an opposite surface (822) of the first conductor (811), the opposite surface (822) being opposite a opposite surface (821) of the first conductor (811) in order to be in contact with the first conductor (811), and the second terminal (818) presses onto an opposite surface (825) of the second conductor (812), the opposite surface (825) being opposite an opposite surface (824) of the second conductor (812) in order to be in contact with the second conductor (812).

Description

Technical area

[0001] The present invention relates to a filter circuit device and a power converter comprising the filter circuit device. In particular, the present invention relates to a filter circuit device and a power converter comprising the filter circuit device, each used in an electric vehicle. Current state of the art

[0002] An electric or hybrid vehicle is equipped with a power converter designed to drive a rotating electric motor using electricity from a battery. The power converter for the electric or hybrid vehicle must meet high miniaturization requirements to ensure sufficient space for its integration within the vehicle.

[0003] Due to the miniaturization of the power converter, along with the close proximity of components resulting from this miniaturization, noise propagation between the components is expected, necessitating a countermeasure against this noise propagation. Therefore, in some cases, a filter device is provided, comprising a conductor and a core element, the conductor being designed to conduct current (PTL 1).

[0004] However, as the electrification of vehicles progresses rapidly, the power converter must meet a further miniaturization requirement while maintaining or improving a noise reduction function. [0004a]

[0005] Patent literature (PTL) 2 describes a filter component comprising a housing body, a first and a second busbar. PTL 3 describes a connection module comprising an insulating housing, a conductor connection terminal, and at least one busbar rod. List of quotations Patent literature PTL 1: JP 2016 - 24 939 A PTL 2: US 2015 / 0 372 655 A1 PTL 3: DE 10 2007 059 640 A1 Summary of the invention; Technical task

[0006] One object of the present invention is to provide a power converter that is miniaturized while maintaining or improving a noise reduction function. Technical solution

[0007] A filter circuit device according to the present invention comprises: a first core element configured to form a first through-hole; a second core element configured to form a second through-hole; a first conductor configured to pass through the first through-hole and the second through-hole; a second conductor configured to pass through the first through-hole and the second through-hole; a capacitor; a first terminal configured to electrically connect the first conductor to the capacitor; and a second terminal configured to electrically connect the second conductor to the capacitor. In the filter circuit device, the first conductor from the first through-hole to the second through-hole and the second conductor from the first through-hole to the second through-hole have an opposing section between the first conductor and the second conductor.The first terminal presses against an opposite face of the first conductor, with the opposite face being located opposite a face of the first conductor, thus making contact with the first conductor. The second terminal presses against an opposite face of the second conductor, with the opposite face being located opposite a face of the second conductor, thus making contact with the second conductor. Advantageous effects of the invention

[0008] The present invention provides a power converter that is miniaturized while maintaining or improving a noise reduction function. Brief description of the drawings [ Fig. 1] Fig. Figure 1 shows an external perspective view of a power converter 100 according to this embodiment. [ Fig. 2] Fig. Figure 2 shows an exploded view of the power converter 100 according to this embodiment. [ Fig. 3] Fig. Figure 3 shows a perspective view of a filter circuit device 800 according to this embodiment. [ Fig. 4] Fig. Figure 4 shows an exploded view of the filter circuit device 800 according to this embodiment. [ Fig. 5] Fig. Figure 5 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line AA in Fig. 3. [ Fig. 6] Fig. Figure 6 shows an enlarged view of area C of the cross-sectional view of the in Fig. 5 shown filter circuit device 800. [ Fig. 7] Fig. Figure 7 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line BB in Fig. 3. [ Fig. 8] Fig. Figure 8 shows an enlarged view of area D of the cross-sectional view of the in Fig. 7 shown filter circuit device 800. [ Fig. 9] Fig. Figure 9 shows a rear view of the filter circuit device 800, that is, the view according to arrow E in Fig. 3. [ Fig. 10] Fig. Figure 10 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line FF in Fig. 9. [ Fig. 11] Fig. Figure 11 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line GG in Fig. 9. [ Fig. 12] Fig. Figure 12 shows a top view of the filter circuit device 800, that is, the view according to arrow H in Fig. 3. [ Fig. 13] Fig. Figure 13 shows an enlarged partial view of area I of the in Fig. 12 shown filter circuit device 800. [ Fig. 14] Fig. Figure 14 shows a front view of a state in which a first core element 814, a second core element 816 and a GS conductor 810 are assembled. Description of embodiments

[0009] An embodiment of a power converter according to the present invention is described below with reference to the accompanying drawings. In each of the drawings, identical components to those described in the other drawings are designated with the same reference numerals, and a detailed description of these is omitted where necessary.

[0010] Fig. Figure 1 shows an external perspective view of a power converter 100 according to this embodiment. Fig. Figure 2 shows an exploded view of the power converter 100 according to this embodiment.

[0011] A power semiconductor module 300 comprises a multitude of power semiconductor elements and is designed to convert direct current to alternating current through switching operations of the power semiconductor elements. A capacitor module 230 is designed to smooth the direct current and supply the smoothed direct current to the power semiconductor module 300.

[0012] A high-performance GS connector 240 is designed to transmit direct current from a battery to a filter circuit device 800 as described below. An WS conductor 400 is designed to supply alternating current to the motor.

[0013] A driver circuit board 510 is configured to calculate a driver signal for driving the power semiconductor element and output the driver signal to the power semiconductor module 300. A low-current signal connector 250 is configured to connect an integrated circuit or similar device to a control circuit board 500 for sending / receiving a control command signal or similar. The control circuit board 500 generates a control signal for controlling the driver circuit board 510 based on the control command signal and outputs the control signal to the driver circuit board 510.

[0014] A metal base plate 280 is arranged between the control circuit board 500 and the driver circuit board 510. The metal base plate 280 is connected to a grounded housing 200. The metal base plate 280 serves as a shielding plate to shield against noise generated by the power semiconductor module 300, the driver circuit board 510, and similar components.

[0015] The housing box 200 has an associated excitation connector 260 and the excitation connector 260 is designed to transmit an excitation signal to an excitation circuit module 600.

[0016] In this embodiment, the housing box 200 includes a screw hole and thus the excitation connector 260 is connected to the housing box 200 by a screw, but can also be connected by other methods.

[0017] The housing box 200 also has an associated filter circuit cover 290, so that the filter circuit cover 290 covers the filter circuit device 800. The capacitor module 230 has an electrical charge stored therein, and a discharge resistor 700 discharges the electrical charge.

[0018] The housing box 200 accommodates the capacitor module 230 in a side compartment thereof (in a lower area of ​​the power converter 100 in Fig. 2) and accommodates the other previously described electrical circuit components in the other side space of this (in an upper area of ​​the converter 100 in Fig. 2) on.

[0019] The housing box 200 has a coolant inlet pipe 210IN and a coolant outlet pipe 210OUT mounted on it to cause coolant to flow in and out.

[0020] Once the housing box 200 has received each component, a lower housing box cover 220 and an upper housing box cover 270 are each mounted onto the housing box 200.

[0021] Fig. Figure 3 shows a general perspective view of the filter circuit device 800 according to this embodiment.

[0022] Fig. Figure 4 shows an exploded view of the filter circuit device 800 according to this embodiment.

[0023] The filter circuit device 800 comprises a DC conductor 810 and a capacitor circuit 850.

[0024] As in Fig. As shown in Figure 4, the GS conductor 810 comprises a first conductor 811, a second conductor 812, a first core element 814, a second core element 816, a first terminal 817, a second terminal 818, and a resin fastening part 819. The first core element 814 forms a first through-hole 813, and the second core element 816 forms a second through-hole 815. The first terminal 817 electrically connects the first conductor 811 to the capacitor circuit 850, and the second terminal 818 electrically connects the second conductor 812 to the capacitor circuit 850.

[0025] The first ladder 811 passes through both the first through-hole 813 and the second through-hole 815. The second ladder 812 passes through both the first through-hole 813 and the second through-hole 815.

[0026] The capacitor circuit 850 comprises a first common-mode capacitor 851, a second common-mode capacitor 852, and two Gaussian noise capacitors 853, which together form a noise suppression unit. The capacitor circuit 850 includes a capacitor housing 854, which provides a space for accommodating the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853.

[0027] In this embodiment, the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853 are combined and housed together in the capacitor housing 854. Alternatively, the capacitor housing 854 can be present in a plurality of numbers, and the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853 can be arranged separately in two or more of the capacitor housings 854. Alternatively, the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853 can be combined with other methods in addition to the capacitor housing 854.

[0028] In the capacitor circuit 850, the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853 are each electrically connected to the first terminal 817 via a first relay terminal 855. Likewise, the first common-mode capacitor 851, the second common-mode capacitor 852, and the two Gaussian noise capacitors 853 are each electrically connected to the second terminal 818 via a second relay terminal 856. The two Gaussian noise capacitors 853 are grounded via a ground terminal 857.

[0029] The capacitor housing 854 has an opening; a capacitor 858 serves as a cover for the opening of the capacitor housing 854.

[0030] In this embodiment, the capacitor circuit 850 comprises two common-mode capacitors, namely the first common-mode capacitor 852 and the second common-mode capacitor 853, each with different capacitances, but can alternatively comprise fewer than two common-mode capacitors or three or more common-mode capacitors.

[0031] Fig. Figure 5 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line AA in Fig. 3.

[0032] As in Fig. As shown in Figure 5, the first conductor 811 and the second conductor 812 each have a main surface and pass through the through-hole 813 and the second through-hole 815, respectively. The main surface of the first conductor 811 and the main surface of the second conductor 812 are opposite each other to form an opposing part 820. Here, the main surface of the first conductor 811 and the main surface of the second conductor 812 each represent a surface that is larger in area than the other surfaces thereof.

[0033] Fig. Figure 6 shows an enlarged view of area C of the cross-sectional view of the in Fig. 5 shown filter circuit device 800.

[0034] The first conductor 811 comprises an opposing surface 821 and an opposing surface 822, which is opposite the opposing surface 821. The first terminal 817 presses the opposing surface 822 of the first conductor 811 against it, so that it is in contact with the first conductor 811.

[0035] In this embodiment, the first terminal 817 is a spring plate element and is inserted into the resin mounting part 819 and an insertion chamber 823 for the first conductor 811. When the first terminal 817 is inserted into the insertion chamber 823, a reaction force is generated. The reaction force causes the first terminal 817 to press against the opposite surface 822 of the first conductor 811. The first terminal 817 can be caused to press against the first conductor 811 by other means, such as other elements.

[0036] Fig. Figure 7 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line BB in Fig. 3. Fig. Figure 8 shows an enlarged view of area D of the cross-sectional view of the in Fig. 7 shown filter circuit device 800.

[0037] The second conductor 812 comprises an opposing surface 824 and an opposing surface 825, which is opposite the opposing surface 824. The second terminal 818 presses the opposing surface 825 of the second conductor 812 against it, so that it is in contact with the second conductor 812.

[0038] In this embodiment, the second terminal 818 is a spring plate element and is inserted into the resin mounting part 819 and an insertion chamber 826 for the second conductor 812. When the second terminal 818 is inserted into the insertion chamber 826, a reaction force is generated. The reaction force causes the second terminal 818 to press against the opposite surface 825 of the second conductor 812. The second terminal 818 can be caused to press against the second conductor 812 by other means, such as other elements.

[0039] The following describes the principles of the invention according to this embodiment. When current flows through a conductor, such as the first conductor 811 or the second conductor 812, a magnetic field is generated around the conductor, and this magnetic field generates noise.

[0040] However, if the conductor passes through a core of each of the first core element 814 and the second core element 816, the core forms an inductor. The inductor has an impedance that increases with respect to a high-frequency component. Thus, it is less likely that a high-frequency noise component will pass through the inductor, and the inductor exhibits a low-pass filter-like performance.

[0041] In this embodiment, the first conductor 811 and the second conductor 812 penetrate the first core element 814 and the second core element 816, respectively. This means that the first core element 814 and the second core element 816 each have double noise filters formed within them. This configuration improves the noise reduction performance.

[0042] A power converter must meet requirements regarding weight reduction, miniaturization, and cost reduction. Therefore, a noise filter integrated into the power converter must be lightweight / small and inexpensive, while still possessing a high noise reduction capability.

[0043] This embodiment uses a small core while maintaining noise elimination capabilities. Simultaneously, this embodiment employs a conductor penetrating the core that does not require a large fastening component, such as a large pin. One purpose of avoiding the mounting of a large pin or similar component is to prevent an increase in weight, space, or cost due to an increase in the number of components. Additionally, a smaller number of components can lead to a reduction in the number of assembly processes, thereby improving assembly efficiency and reducing costs.

[0044] In addition to using the core, a capacitor can serve as a further means of noise reduction. The capacitor has an impedance that increases with respect to a low-frequency component. Thus, it is less likely that a low-frequency noise component will pass through the capacitor, and the capacitor exhibits performance similar to a high-pass filter. In this embodiment, a variety of capacitors with different capacitances are used to improve the noise reduction performance in each specified low-frequency band.

[0045] Pressing can serve as a means of joining the conductors together. The first conductor 811 and the second conductor 812 have the opposite part 820 between them. The first terminal 817 and the second terminal 818 are each caused to press against the corresponding opposite surface, which is opposite the opposite part 820. (The first terminal 817 presses against the opposite surface 822 of the first conductor 811, and the second terminal 818 presses against the opposite surface 825 of the second conductor 812.)

[0046] Accordingly, in this embodiment, even with a structure using an undivided type of core, the ability to eliminate noise is not impaired, and the smaller number of components can lead to weight reduction, miniaturization, cost reduction, and improved assembly efficiency.

[0047] Fig. Figure 9 shows a rear view of the filter circuit device 800, that is, the view according to arrow E in Fig. 3. Fig. Figure 10 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line FF in Fig. 9. Fig. Figure 11 shows a cross-sectional view along a plane perpendicular to a surface of the filter circuit device 800 comprising an arrow line GG in Fig. 9.

[0048] As in Fig. As shown in Figure 10, the first connection 817 is pressed against the opposite surface 822 of the first conductor 811 by a first pressing element 827. As in Fig. As shown in Figure 11, the second connection 818 is pressed against the opposite surface 825 of the second conductor 818 by a second pressing element 828, similar to the first connection 817.

[0049] The first pressing element 827 and the second pressing element 828 are each a screw mechanism, but can be any other element that can press the first connection 817 and the second connection 818.

[0050] Fig. Figure 12 shows a top view of the filter circuit device 800, that is, the view according to arrow H in Fig. 3. Fig. Figure 12 also shows a view of the filter circuit device 800 when viewed from a direction perpendicular to the opposite surface 821 of the first conductor 811.

[0051] As in Fig. Figure 12 shows that the first terminal 817 and the second terminal 818 are arranged without overlapping each other and the capacitor circuit 850 is arranged such that its part is located between the first terminal 817 and the second terminal 818.

[0052] As a means of reducing the number of assembly processes and improving assembly efficiency, the screws of the first press element 827 and the second press element 828 can be designed for insertion in the same direction.

[0053] In this embodiment, the filter circuit device 800 is designed for insertion into the housing of the power converter in a direction perpendicular to the opposite surface 821 before being fixed with screws. With this configuration, the housing can be screwed together without changing its orientation, and assembly efficiency can be improved.

[0054] Furthermore, dead space can be reduced as a means of saving space for arranging components. In this embodiment, the housing box has a limited space for accommodating the filter circuit device 800, and the dimensions of each capacitor to be used are limited. Accordingly, the capacitor circuit 850 must have as little dead space as possible.

[0055] As in Fig. Figure 12 shows that the capacitor circuit 850 is inserted into the dead space between the first core element 814 and the second core element 816, and simultaneously the capacitor circuit 850 is arranged in the position between the first terminal 817 and the second terminal 818. Thus, the dead space is reduced.

[0056] Fig. Figure 13 shows an enlarged partial view of area I of the in Fig. 12 shown filter circuit device 800.

[0057] In this embodiment, the capacitors to be used are arranged together in the capacitor circuit 850, and each of the terminals for these capacitors is a cylindrical terminal wire. For easy electrical connection to these capacitors, the terminals for the capacitors can be welded or soldered to the capacitors. In this state, the capacitor circuit 850 must be designed such that breakage of these welded or soldered parts by external force is prevented. Thus, in this embodiment, during the assembly of the capacitor circuit 850, a first capacitor-side terminal 859 and a second capacitor-side terminal 860 are installed in the capacitor circuit 850 before they are welded or soldered to the capacitors.With this configuration, the welded or soldered connections are securely electrically connected to the capacitors, and the welded or soldered parts are less exposed to external forces.

[0058] The first terminal 817 comprises the first capacitor-side terminal 859 and a first conductor-side terminal 829. The first capacitor-side terminal 859 is located closer to the first capacitor on one side. The first conductor-side terminal 829 is a separate element from the first conductor-side terminal 859 and is in contact with the first conductor 811.

[0059] The second terminal 818 comprises the second capacitor-side terminal 860 and a second conductor-side terminal 830. The second capacitor-side terminal 860 is located closer to the second capacitor on one side. The second conductor-side terminal 830 is a separate element from the second conductor-side terminal 860 and is in contact with the second conductor 812.

[0060] Fig. Figure 14 shows a front view of a state in which the first core element 814, the second core element 816 and the GS conductor 810 are assembled.

[0061] The resin fastening part 819 supports first core element 814, second core element 816, first conductor 811, second conductor 812, first conductor-side connection 829 and second conductor-side connection 830.

[0062] With this configuration, each component is combined into a single subassembly, resulting in improved assembly efficiency. The resin mounting part 819 also serves to insulate and prevent a short circuit between the first conductor 811, second conductor 812, first conductor-side terminal 829, and second conductor-side terminal 830, through which current flows. Reference symbol list 100 power converters 200 housing boxes 210IN Coolant Inlet Pipe 2100UT Coolant Outlet Pipe 230 capacitor module 240 high-performance GS connectors 250 low-voltage signal connectors 260 excitation connectors 280 metal base plate 290 Filter circuit cover 300 Power Semiconductor Module 400 WS conductors 500 control circuit board 510 driver circuit board 700 discharge resistor 800 filter circuit device 810 WS conductors 811 first leader 812 second conductor 813 first through hole 814 first core element 815 second through hole 816 second core element 817 first connection 818 second connection 819 Resin fastening part 820 opposite part 821 opposite area 822 opposite area 823 Introduction chamber 825 opposite area 826 Introduction chamber 827 first pressing element 828 second pressing element 829 first conductor-side connection 830 second conductor-side connection 850 capacitor circuit 851 first common-mode capacitor 852 second common-mode capacitor 853 Gauss noise capacitor 854 Capacitor housing 855 first relay connection 856 second relay connection 857 Earthing connection 858 Capacitor cover 859 first capacitor-side connection 860 second capacitor-side connection

Claims

[1] Filter circuit device comprising: a first core element (814) configured to form a first through-hole (813); a second core element (816) configured to form a second through-hole (815); a first conductor (811) configured to pass through the first through-hole (813) and the second through-hole (815); a second conductor (812) configured to pass through the first through-hole (813) and the second through-hole (815); a capacitor; a first terminal (817) configured to electrically connect the first conductor (811) to the capacitor; and a second terminal (818) configured to electrically connect the second conductor (812) to the capacitor, where the first conductor (811) from the first through-hole (813) to the second through-hole (815) and the second conductor (812) from the first through-hole (813) to the second through-hole (815) have an opposite part (820) between the first conductor (811) and the second conductor (812), the first terminal (817) presses onto an opposite surface (822) of the first conductor (811), the opposite surface (822) being opposite an opposite surface (821) of the first conductor (811) to be in contact with the first conductor (811), and the second terminal (818) presses onto an opposing surface (825) of the second conductor (812), the opposing surface (825) being opposite an opposing surface (824) of the second conductor (812) to be in contact with the second conductor (812). [2] The filter circuit device according to claim 1, further comprising: a first pressing element (827) configured to press the first terminal (817) onto the first conductor (811); and a second pressing element (828) configured to press the second terminal (818) onto the second conductor (812). [3] Filter circuit device according to claim 1 or 2, wherein, when viewed from a direction perpendicular to the opposite surface (821) of the first conductor (811), the first terminal (817) and the second terminal (818) are arranged at a position where the first terminal (817) and the second terminal (818) do not overlap with each other, and the capacitor is arranged at a location where the capacitor is arranged between the first terminal (817) and the second terminal (818). [4] Filter circuit device according to one of claims 1 to 3, wherein the first terminal (817) comprises: a first capacitor-side terminal (859) arranged on a side closer to the capacitor; and a first conductor-side terminal (829) formed on a member different from the first capacitor-side terminal (859) and in contact with the first conductor (811), and the second terminal (818) comprises: a second capacitor-side terminal (860) arranged on a side closer to the capacitor; and a second conductor-side terminal (830) formed on a member different from the second capacitor-side terminal (860) and in contact with the second conductor (812). [5] The filter circuit device according to claim 4, further comprising a resin fixing part (819) configured to support the first core member (814), the second core member (816), the first conductor (811), the second conductor (812), the first conductor-side terminal (829), and the second conductor-side terminal (830). [6] Power converter comprising the filter circuit device (800) according to one of claims 1 to 5, wherein the power converter (100) comprises: a power semiconductor module (300) designed to convert direct current into alternating current; and a capacitor module (230) designed to smooth the direct current, where the filter circuit removes noise from the direct current supplied to the capacitor module (230). [7] Power converter according to claim 6, further comprising: a housing configured to form space for accommodating the power semiconductor module (300) and the filter circuit device (800); and a cover configured to be arranged in the space between the power semiconductor module (300) and the filter circuit device (800) and to be connected to the housing.

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