Power control device

Abstract

To provide a power control device suppressing adverse effects due to flux leakage of a reactor.SOLUTION: A power control device 2 has a reactor unit 7 and a sensor unit 9. The reactor unit 7 and the sensor unit 9 are arranged adjacently in X direction. A reactor element 40 has a core 45 and a coil 46. The sensor unit 9 has a current measuring part 30. A shortest distance between a first core 41 and the current measuring part 30 is a distance D1. A shortest distance between a second core 42 and the current measuring part 30 is a distance D2. Under an adjacent relation, the distance D2 between the second core 42 whose permeability is not minimum and the current measuring part 30 is shorter than the distance D1 between the first core 41 also called another core and the current measuring part 30. By satisfying the distance relation, an influence to the current measuring part 30 from the first core 41 is suppressed.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The disclosure herein relates to a power control device. [Background technology]

[0002] Patent Document 1 discloses a reactor. The reactor includes a shielding member that suppresses leakage magnetic flux. Patent Document 2 discloses a power control device. The power control device includes a reactor and a current sensor. The reactor and the current sensor are arranged close to each other. Patent Document 3 discloses a current sensor. The current sensor includes at least one magnetic shield. The contents of the prior art documents are incorporated by reference as explanations of the technical elements in this specification. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-80021 A [Patent Document 2] JP 2012-105370 A [Patent Document 3] Patent No. 6919609 Summary of the Invention [Problem to be solved by the invention]

[0004] The reactor in the prior art document is an electromagnetic element, and therefore generates leakage flux. The leakage flux may affect the function of electrical components arranged in close proximity. The leakage flux may induce noise in an electrical circuit by electromagnetic induction. There is concern that such noise may cause adverse effects such as a decrease in the function of electrical components. For example, there is concern that the function of sensor elements such as temperature sensors and current sensors may decrease. Furthermore, elements that utilize electromagnetic effects are more directly susceptible to leakage flux. For example, there is concern that a current sensor that detects current by utilizing electromagnetic effects may be adversely affected by an increase in noise components and an error in the detected current. In the above-mentioned respects, or in other respects not mentioned, further improvements are required for the power control device.

[0005] One disclosed object is to provide a power control device in which adverse effects caused by leakage magnetic flux of a reactor are suppressed.

[0006] Another disclosed object is to provide a power control device that suppresses degradation in performance of a current sensor caused by leakage magnetic flux of a reactor. [Means for solving the problem]

[0007] The power control device (2) disclosed herein is a power control device (2) that converts electric power, and includes a conductive member (2a) for passing a current to be converted, a coil (46) electrically connected to the conductive member, a reactor element (40) having a core (45) through which magnetic flux induced in the coil passes, and an electrical component (30) that is an electrical component in the power control device and is affected by leakage magnetic flux from the core, the core including at least a first core (41) having a first magnetic permeability (M1) and a second core having a second magnetic permeability (M2) greater than the first magnetic permeability, a first distance (D1) as a path of magnetic flux is formed between the first core and the electrical component, a second distance (D2) as a path of magnetic flux is formed between the second core and the electrical component, and the core and the electrical component are arranged such that a distance relationship (D1>D2) in which the second distance is shorter than the first distance is satisfied.

[0008] According to the disclosed power control device, the second core has a second permeability higher than the first permeability of the first core. Thus, the leakage flux from the second core is less than the leakage flux from the first core. Therefore, the influence of the leakage flux of the second core on the electrical components due to the permeability is small. Furthermore, the reactor element and the electrical components are arranged to satisfy a distance relationship in which the first distance is shorter than the second distance. Therefore, the influence of the leakage flux of the first core on the electrical components due to the distance relationship is suppressed.

[0009] The various embodiments disclosed in this specification employ different technical means to achieve their respective objectives. The claims and the parenthetical symbols described in this section are merely illustrative of the corresponding relationship with the embodiments described below, and are not intended to limit the technical scope. The objectives, features, and effects disclosed in this specification will become more apparent by referring to the following detailed description and the accompanying drawings. [Brief description of the drawings]

[0010] [Figure 1] 1 is a block diagram of a power control device according to a first embodiment. [Diagram 2] FIG. [Diagram 3] FIG. [Figure 4] 4 is a perspective view of the reactor and the sensor unit taken along the line IV in FIG. 2 . [Diagram 5] FIG. 11 is a perspective view of a reactor unit and a sensor unit according to a second embodiment. [Figure 6] FIG. 11 is a perspective view of a reactor unit and a sensor unit according to a third embodiment. [Figure 7] FIG. 13 is a perspective view of a reactor unit and a sensor unit according to a fourth embodiment. [Figure 8] FIG. 13 is a perspective view of a reactor unit and a sensor unit according to a fifth embodiment. [Figure 9]FIG. 13 is a perspective view of a reactor unit and a sensor unit according to a sixth embodiment. [Figure 10] FIG. 13 is a perspective view of a reactor unit and a sensor unit according to a seventh embodiment. [Figure 11] FIG. 13 is a perspective view of a reactor unit and a sensor unit according to an eighth embodiment. [Figure 12] FIG. 13 is a perspective view of a reactor unit and a sensor unit according to a ninth embodiment. [Figure 13] FIG. 23 is a perspective view of a reactor unit and a sensor unit according to a tenth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] A number of embodiments will be described with reference to the drawings. In a number of embodiments, functionally and / or structurally corresponding and / or associated parts may be given the same reference numerals or reference numerals with different digits of 100 or more. For corresponding and / or associated parts, reference may be made to the description of other embodiments.

[0012] First embodiment FIG. 1 is a block diagram showing a vehicle power system 1. In this embodiment, the vehicle is a vehicle that travels on the ground. The vehicle is an electric vehicle powered by a rotating electric machine that provides running power by electricity. The vehicle may additionally include an internal combustion engine that provides running power by fuel. The vehicle is also called a hybrid vehicle, a plug-in hybrid vehicle, a battery-electric vehicle, etc. The vehicle may be a ship that travels on water, an aircraft that travels in the air, or a spacecraft in outer space.

[0013] The power system 1 includes a power control device 2. The power control device 2 is electrically connected and disposed between a battery 3 and a rotating electric machine 4. The power control device 2 provides bidirectional conversion or unidirectional conversion between DC and AC. Furthermore, the power control device 2 provides DC power regulation and / or AC power regulation. The power control device 2 provides DCAC conversion to convert DC power supplied from the battery 3 into AC power and supply it to the rotating electric machine 4. Furthermore, the power control device 2 provides ACDC conversion to convert AC power supplied from the rotating electric machine 4 into DC power and charge the battery 3.

[0014] The power system 1 includes a battery 3. The battery 3 is a DC power source. In this embodiment, the battery 3 is a secondary battery that can be charged and discharged. The DC power source can be any of a variety of batteries, such as a lead-acid battery, a lithium-ion battery, or a nickel-cadmium battery. Furthermore, the DC power source may be provided by a fuel cell.

[0015] The power system 1 includes a rotating electric machine 4. One example of the rotating electric machine 4 is an electric motor. Another example of the rotating electric machine 4 is a generator motor (MG). One example of the rotating electric machine 4 is an AC rotating electric machine. One example of the rotating electric machine 4 is a multi-phase AC rotating electric machine. In this embodiment, the rotating electric machine 4 is a three-phase AC rotating electric machine.

[0016] The power control device 2 has a converter (CONV) 5 and an inverter (INV) 6. The converter 5 and the inverter 6 are connected in series and arranged between the battery 3 and the rotating electric machine 4. The power control device 2 converts electric power. The power control device 2 is also called a power conversion device. The power control device 2 includes a conductive member 2a for passing a current to be converted. The conductive member 2a is a member for passing a large current to be converted. The conductive member 2a is provided by a bus bar. The conductive member 2a may be laid out vertically and horizontally within the power control device 2 to enable efficient current flow. The conductive member 2a is arranged between the converter 5 and the inverter 6, between the inverter 6 and the rotating electric machine 4, and the like.

[0017] The converter 5 has a primary end and a secondary end. In this embodiment, the battery 3 is connected to the primary end, and the inverter 6 is connected to the secondary end. The converter 5 provides a step-up function for boosting a voltage between the primary end and the secondary end. The converter 5 provides a step-down function for lowering a voltage between the primary end and the secondary end. The converter 5 provides a step-up function and / or a step-down function. The converter 5 is provided by a chopper circuit. The chopper circuit includes a reactor unit (L) 7 and a switching element. The reactor unit 7 is an electromagnetic element that converts power energy and magnetic energy into each other. The converter 5 may be provided by a circuit including a transformer. In this case, the transformer is the electromagnetic element.

[0018] The inverter 6 has a DC end and an AC end. In this embodiment, the converter 5 is connected to the DC end, and the rotating electric machine 4 is connected to the AC end. The inverter 6 provides a DCAC conversion function of converting DC power input to the DC end into AC power and outputting it to the AC end. The inverter 6 provides an ACDC conversion function of converting AC power input to the AC end into DC power and outputting it to the DC end. The inverter 6 provides the DCAC conversion function and / or the ACDC conversion function. The AC end has a plurality of terminals corresponding to multi-phase AC. In the illustrated example, the AC end corresponds to three-phase AC. The inverter 6 is provided by a bridge circuit including a plurality of switching arms. The multiple switching arms are provided by a plurality of switching elements.

[0019] The switching elements of the converter 5 and the inverter 6 may be provided by the same type of elements or different types of elements. The switching elements may be provided by a switch module including one or more switching elements. The switching elements may be provided by a variety of switching elements, such as IGBTs, power MOS, SiC elements, etc.

[0020] The power control device 2 has a capacitor unit (C) 8. The capacitor unit 8 includes a capacitor element connected between a positive electrode member and a negative electrode member between the converter 5 and the inverter 6. This capacitor unit 8 smoothes the DC power between the converter 5 and the inverter 6.

[0021] The power control device 2 has a sensor unit 9. The sensor unit 9 measures the current of a current path in the power control device 2 and outputs an electric signal indicating the amount of current. The sensor unit 9 has at least one current measurement unit 30 for measuring the current of at least one current path. The current measurement unit 30 is an electric component in the power control device 2. The current measurement unit 30 is an electric component that is affected by leakage magnetic flux from a core of a reactor element described later. The current measurement unit 30 is an electromagnetic component that detects magnetic flux caused by a current flowing through a conductive member. In this embodiment, the sensor unit 9 has a plurality of current measurement units 30. In this case, the sensor unit 9 is also called a current sensor unit. The plurality of current measurement units 30 include at least a plurality of current measurement units 30 that measure a multi-phase current flowing between the inverter 6 and the rotating electric machine 4. The plurality of current measurement units 30 include at least one current measurement unit 30 that measures a direct current flowing between the converter 5 and the inverter 6. In the illustrated example, the sensor unit 9 has at least four current measurement units 30. The sensor unit 9 outputs a plurality of detection signals. The detection signals of the sensor unit 9 are input to a control circuit 10, which will be described later.

[0022] The sensor unit 9 includes a housing formed mainly from an electrically insulating resin material. The housing holds a conductive member through which a current to be detected flows. The housing may include a plurality of conductive members. The housing holds a plurality of components constituting a current measuring unit 30. The housing may include a plurality of current measuring units 30. Each of the plurality of current measuring units 30 is disposed and functions in correspondence with each of the plurality of conductive members.

[0023] The sensor unit 9 may have a plurality of partial units separated from each other. Each of the plurality of partial units may include a respective one of a plurality of conductive members, or two or more of them. In this case, each of the plurality of partial units includes a current measuring unit 30 corresponding to the conductive member associated therewith. Even in such a case, the power control device 2 has the sensor unit 9 including the plurality of partial units.

[0024] The current measuring unit 30 utilizes electromagnetic effects. The current measuring unit 30 has a measuring element. The current measuring unit 30 positions the measuring element so as to face the conductive member through which the current to be measured flows, without being in direct contact with the conductive member. The current measuring unit 30 outputs an electrical signal indicating the current measured by the measuring element.

[0025] The power control device 2 includes a control circuit 10. The control circuit 10 receives an electrical signal from the sensor unit 9. The control circuit 10 controls at least one switching element in the converter 5 and the inverter 6. The control circuit 10 controls the on-timing and / or the off-timing of the switching element. The control circuit 10 controls the voltage supplied to the rotating electric machine 4 and / or the current supplied to the rotating electric machine 4 by controlling the switching element. The control circuit 10 controls the voltage supplied to the battery 3 and / or the current supplied to the battery 3 by controlling the switching element.

[0026] The control circuit in this specification may also be called an electronic control unit (ECU). The control circuit may also be called a control system.

[0027] The control circuit is provided by a control system including at least one computer. The control system is provided by an algorithm as (a) a plurality of logics called if-then-else form, or (b) a trained model tuned by machine learning, for example, a neural network. The control system may include a plurality of computers linked by a data communication device. The computer includes at least one processor that is hardware (hardware processor). The hardware processor may be provided by the following (i), (ii), or (iii).

[0028] (i) The hardware processor may be at least one processor core that executes a program stored in at least one memory. In this case, the computer is provided with at least one memory and at least one processor core. The processor core is called a CPU (Central Processing Unit), a GPU (Graphics Processing Unit), a RISC-CPU, etc. The memory is also called a storage medium. The memory is a non-transient and tangible storage medium that non-temporarily stores "programs and / or data" that can be read by the processor. The storage medium is provided by a semiconductor memory, a magnetic disk, an optical disk, or the like. The program may be distributed alone or as a storage medium on which the program is stored.

[0029] (ii) The hardware processor may be a hardware logic circuit. In this case, the computer is provided by a digital circuit including a large number of programmed logic units (gate circuits). The digital circuit is also called a logic circuit array, for example, ASIC: Application-Specific Integrated Circuit, FPGA: Field Programmable Gate Array, SoC: System on a Chip, PGA: Programmable Gate Array, CPLD: Complex Programmable Logic Device, etc. The digital circuit may include a memory that stores programs and / or data. The computer may be provided by an analog circuit. The computer may be provided by a combination of digital and analog circuits.

[0030] (iii) The hardware processor may be a combination of (i) and (ii) above. (i) and (ii) may be located on different chips or on a common chip. In these cases, the (ii) part may also be called an accelerator.

[0031] The control system and the control method executed by the control system described in this disclosure may be realized by a special-purpose computer provided by configuring a processor and a memory programmed to execute one or more functions embodied in a computer program. Alternatively, the control unit and the method described in this disclosure may be realized by a special-purpose computer provided by configuring a processor with one or more dedicated hardware logic circuits. Alternatively, the control unit and the method described in this disclosure may be realized by one or more special-purpose computers configured by a combination of a processor and a memory programmed to execute one or more functions and a processor configured with one or more hardware logic circuits. Also, the computer program may be stored in a computer-readable non-transitory tangible recording medium as instructions executed by a computer.

[0032] 2 shows an example of the installation posture of the power control device 2 and the arrangement of components inside the power control device 2. As shown in the figure, the components of the power control device 2 are housed in a housing 20. The housing 20 is made of resin or metal. From the viewpoint of suppressing electromagnetic noise emitted from the power control device 2 and / or from the viewpoint of suppressing electromagnetic noise arriving from outside the power control device 2, it may be desirable for the housing 20 to be made of a material having an electromagnetic shielding effect.

[0033] The power control device 2, i.e., the housing 20, has a three-dimensional shape with an internal volume capable of accommodating a plurality of components. The housing 20 has a three-dimensional shape with a width in the width direction (x direction), a height in the height direction (y direction), and a depth in the depth direction (z direction). Note that FIG. 2 is merely an example of an installation posture of the power control device 2. The power control device 2 can be installed in various postures, such as vertical, horizontal, and oblique. Also, FIG. 2 is merely an example of an arrangement of a plurality of components in the housing 20. The plurality of components may be arranged such that two components are stacked vertically and / or two components are aligned horizontally. The names of the width, height, and depth shown in the figure are convenient names that represent the installation state shown in the figure.

[0034] The sensor unit 9 has a plurality of current measuring sections 30. The plurality of current measuring sections 30 are arranged in a row along the longitudinal direction of the sensor unit 9, that is, along the depth direction (z direction) in the figure.

[0035] The reactor unit 7 has a plurality of reactor elements 40. The reactor elements 40 are electromagnetic energy storage elements. The plurality of reactor elements 40 are arranged in a row along the longitudinal direction of the reactor unit 7, that is, the depth direction (z direction) in the figure. The plurality of reactor elements 40 may be arranged in one row or in a plurality of rows.

[0036] The components of the power control device 2 include a converter 5 and an inverter 6. The components of the power control device 2 further include a reactor unit 7, a capacitor unit 8, a sensor unit 9, and a control circuit 10. The reactor unit 7 and the capacitor unit 8 are also circuit elements of the converter 5. The converter 5 and the inverter 6 include a plurality of switching elements that are their main circuit elements. The power control device 2 includes a heat dissipation module 11 for dissipating heat from the plurality of switching elements.

[0037] The multiple switching elements are incorporated in the heat dissipation module 11. For example, the multiple switching elements may be provided by multiple switch modules 12. One switch module 12 may be provided by a semiconductor package having a rectangular flat plate-like appearance. The heat dissipation module 11 is arranged to contact one or both sides of the multiple switch modules 12 so as to enable heat dissipation from one or both sides of the multiple switch modules 12. The heat dissipation module 11 defines a medium passage for flowing a heat medium. The heat dissipation module 11 provides heat exchange between the multiple switch modules 12 and the heat medium. In the power system 1, the heat medium includes a heat medium circulation path installed outside the power control device 2. The heat medium circulation path includes a heat exchanger that cools the heat medium. The heat medium receives heat from the heat dissipation module 11 by flowing through the heat dissipation module 11. Furthermore, the heat medium passes through the heat exchanger by flowing through the heat medium circulation path to release heat. For example, the heat of the heat medium is released to the outside air. The heat of the heat medium may be dissipated through a refrigeration cycle.

[0038] As shown in FIG. 2, the components of the power control device 2 are disposed adjacent to one another in a housing 20. The shape of the housing 20 and the layout of the components in the housing 20 are set in response to various requirements. One of the various requirements is to enable mounting of the power system 1. One of the various requirements is to suppress Joule heat inside the power control device 2. One of the various requirements is to suppress inductance components and / or capacitance components that affect the high-frequency characteristics of the power control device 2. Therefore, it should be understood that the layout of the components shown in FIG. 2 is merely exemplary, and that various modifications of the layout of the components are possible.

[0039] The reactor unit 7 and the sensor unit 9 are disposed adjacent to each other in any direction. In the illustrated example, the reactor unit 7 and the sensor unit 9 are disposed adjacent to each other in the width direction (x direction). The reactor unit 7 and the sensor unit 9 are also adjacent to each other in the diagonal directions between the width direction (x direction) and the depth direction (z direction). However, here, the direction that defines the shortest distance, i.e., the width direction (x direction), is defined as the adjacent direction.

[0040] The reactor unit 7 and the sensor unit 9 are arranged so that the reactor element 40 and the current measurement section 30 are adjacent to each other in any direction. As a result, the reactor element 40 and the current measurement section 30 are arranged so that they are adjacent to each other in any direction. In the illustrated example, the reactor element 40 and the current measurement section 30 are arranged adjacent to each other in the width direction (x direction). The reactor element 40 and the current measurement section 30 are also adjacent to each other in the diagonal directions between the width direction (x direction) and the depth direction (z direction). However, here, the direction that defines the shortest distance, i.e., the width direction (x direction), is defined as the adjacent direction.

[0041] The reactor unit 7 and the sensor unit 9 are adjacent to each other such that an outer wall surface of the reactor unit 7 and an outer wall surface of the sensor unit 9 are positioned parallel to each other. This arrangement enables the reactor element 40 and the current measurement unit 30 to be positioned close to each other. Furthermore, this arrangement contributes to a reduction in the size of the power control device 2. The reactor unit 7 and the sensor unit 9 may be positioned such that an outer wall surface of the reactor unit 7 and an outer wall surface of the sensor unit 9 face each other non-parallel to each other.

[0042] Between the reactor element 40 and the current measuring section 30, a resin member that provides a housing for the reactor unit 7 and / or a resin member that provides a housing for the sensor unit 9 is disposed.

[0043] In FIG. 2, the reactor unit 7 and the switch module 12 are adjacent to each other in an arbitrary direction. The reactor unit 7 and the switch module 12 are adjacent to each other in the height direction (y direction). The switch module 12 may include one or more temperature sensors. The one or more temperature sensors measure the temperature of one portion or multiple portions in the switch module 12 and output a temperature signal indicating the temperature. The temperature signal is input to the control circuit 10. The control circuit 10 performs temperature control based on the temperature signal to protect the switch module 12 and the switching elements. The temperature control is performed on the converter 5 and / or the inverter 6.

[0044] The temperature sensor may be adversely affected by leakage magnetic flux from the reactor element 40. For example, the leakage magnetic flux may electromagnetically affect the detection characteristics of the temperature sensor. The leakage magnetic flux may also electromagnetically heat the temperature sensor, causing a change in the measurement value of the temperature sensor. In these cases, the temperature sensor is affected by the leakage magnetic flux of the reactor element 40.

[0045] 3 shows a cross section of the sensor unit 9. The sensor unit 9 includes a housing 31. The housing 31 holds a plurality of components constituting a current measurement unit 30. The housing 31 holds a conductive member 32. The housing 31 may include a plurality of conductive members 32. The housing 31 may include a plurality of current measurement units 30. One current measurement unit 30 is associated with one conductive member 32. The current measurement unit 30 is positioned at a predetermined position with respect to the conductive member 32 so as to generate a measurement signal indicating a predetermined current value when a predetermined current flows through the conductive member 32.

[0046] The current measuring unit 30 includes a sensor element 33. The sensor element 33 measures the current flowing through the conductive member 32 by utilizing an electromagnetic effect. For example, the sensor element 33 generates a measurement signal in response to a magnetic flux Sf generated around the conductive member 32 in response to the current flowing through the conductive member 32. The sensor element 33 provides a magnetoelectric conversion unit that converts the magnetic flux into an electric signal. The magnetoelectric conversion unit includes a magnetoresistance effect element. The sensor element 33 is provided by a semiconductor chip. The current measuring unit 30 includes a circuit board 34 on which the sensor element 33 is mounted. The circuit board 34 provides a positioning member that positions the sensor element 33 with high accuracy. The circuit board 34 has a circuit for the sensor element 33. The circuit board 34 includes a drive circuit for operating the sensor element 33. Furthermore, the circuit board 34 includes a processing circuit that processes the measurement signal output by the sensor element 33.

[0047] The sensor element 33 includes a magnetic body 33a that is affected by leakage magnetic flux from the reactor element. The circuit board 34 includes a circuit 34a that is affected by leakage magnetic flux from the reactor element. The circuit 34a may be understood as a circuit pattern formed on the circuit board 34. Furthermore, in this embodiment, the current measurement unit 30 includes both the magnetic body 33a and the circuit 34a. Alternatively, the current measurement unit 30 may be configured to include only one of the magnetic body 33a or the circuit 34a.

[0048] The current measuring unit 30 includes a magnetic shielding member 35. The current measuring unit 30 may not include the shielding member 35. The shielding member 35 is an optional part that may be selectively adopted. Compared with the shielding member 35, the housing 31 and the circuit board 34 have a significantly lower magnetic shielding function. The shielding member 35 is made of a ferromagnetic material such as an electromagnetic steel plate. The magnetic flux Sf is generated in the conductive member 32 and can be called an internal magnetic flux measured by the sensor element 33. In this case, the magnetic flux arriving at the current measuring unit 30 from outside the current measuring unit 30 can be called an external magnetic flux Nf.

[0049] The shield member 35 functions as a magnetic guide member that guides the magnetic flux Sf. The shield member 35 stabilizes the magnetic flux Sf that interlinks with the sensor element 33. For example, the sensor element 33 may have a measurement axis that measures magnetic flux in a specific direction. The shield member 35 stabilizes the magnetic flux in the measurement axis among the magnetic flux that attempts to interlink with the sensor element 33. From another perspective, the shield member 35 captures the external magnetic flux Nf. As a result, the shield member 35 suppresses the effect of the external magnetic flux Nf on the sensor element 33.

[0050] The shield member 35 may include a first shield member 36 and a second shield member 37. The conductive member 32 and the sensor element 33 form a part pair that generates an internal magnetic flux Sf and measures the internal magnetic flux Sf. The part pair is arranged to face each other in a predetermined facing direction. The first shield member 36 and the second shield member 37 are arranged to sandwich the part pair from the outside of the part pair in this facing direction. The shield member 35 may be formed of a single member. For example, the shield member 35 may include only either the first shield member 36 or the second shield member 37. For example, the shield member 35 may be provided by a single continuous member including members corresponding to the first shield member 36 and the second shield member 37.

[0051] Regarding the current measuring unit 30, the sensor element 33, and the shielding member 35, the disclosure of Japanese Patent No. 6919609 can be incorporated by reference.

[0052] 4 shows a cross section of the reactor unit 7 and the sensor unit 9 in the xy plane. The reactor unit 7 and the sensor unit 9 are arranged adjacent to each other in the width direction (x direction). The distance between the reactor unit 7 and the sensor unit 9 is short enough that the leakage magnetic flux of the reactor element 40 reaches the current measurement section 30. The distance between the reactor unit 7 and the sensor unit 9 is short enough that the leakage magnetic flux of the reactor element 40 interlinks with the sensor element 33.

[0053] The reactor element 40 and the current measurement unit 30 are disposed adjacent to each other with no member between them that can function as an electromagnetic shield other than the shield member 35. In this arrangement, leakage magnetic flux from the reactor element 40 may affect the current measurement unit 30. For example, the leakage magnetic flux may change the magnetic flux distribution in the current measurement unit 30. Furthermore, the leakage magnetic flux may be directly detected by the current measurement unit 30. In these cases, the current measurement unit 30, which utilizes an electromagnetic effect, is affected by the leakage magnetic flux of the reactor element 40.

[0054] Here, the current measurement unit 30 may include a shield member 35. However, even if the leakage magnetic flux only reaches the shield member 35, the magnetic flux linking the sensor element 33 may change. Therefore, in the following embodiment, the influence of the leakage magnetic flux of the reactor element 40 reaching the current measurement unit 30 including the shield member 35 is also taken into consideration. Note that the current measurement unit 30 shown in FIG. 4 may be used as the position of the sensor element 33 to evaluate the distance, which will be described later.

[0055] The reactor element 40 has a core 45 and a coil 46. The coil 46 is electrically connected to the conductive member 2a. The coil 46 has a conductive member wound around a coil axis CX. In the illustrated example, the coil axis CX is positioned along the x direction. The coil axis CX is arranged to point toward the current measurement unit 30. The coil axis CX is arranged to intersect with the current measurement unit 30. The coil axis CX is arranged to intersect with the sensor element 33. The illustrated coil 46 has a single coil portion. Alternatively, the coil 46 may have multiple coil portions. For example, it is possible to provide multiple coil portions, such as two or three, in multiple magnetic path portions formed by a core 45 described later.

[0056] The core 45 passes the magnetic flux induced in the coil 46. The core 45 is provided by two E-shaped cores. The core 45 is also called an EE core. The two E-shaped cores are arranged to represent an E shape on the xy plane. The two E-shaped cores are arranged and connected so that the three ends of one E-shaped core face the three ends of the other E-shaped core. The core 45 forms a magnetic path MP through which the magnetic flux induced in the coil 46 passes when a current flows through the coil 46. The core 45 can be provided by various layouts including an EE core. For example, various cores such as an EI core, a UI core, a UU core, an OI core, and a UIU core can be adopted instead of the EE core. The core 45 can be provided by various materials such as a laminate of electromagnetic steel sheets and a powder compact.

[0057] In Fig. 4, the magnetic path MP is indicated by a two-dot chain line. The core 45 forms a closed magnetic path MP. The core 45 is a gapless core. The core 45 includes a plurality of cores. The core includes a first core 41 and a second core 42. The junction boundary between the first core 41 and the second core 42 is positioned within the coil 46. However, the core 45 generates leakage magnetic flux.

[0058] The core 45 forms a magnetic path MP. The magnetic path MP extends along the xy plane. The magnetic path MP may include a plurality of magnetic path portions. Furthermore, the magnetic path MP includes a common magnetic path and a plurality of individual magnetic paths. The common magnetic path is a magnetic path common to the plurality of magnetic path portions. The plurality of individual magnetic paths is a magnetic path that characterizes each of the plurality of magnetic path portions. In the illustrated example, the coil 46 is provided in the common magnetic path. Note that the coil 46 may have a plurality of coil portions. In this case, the plurality of coil portions may be provided in a distributed manner in the common magnetic path and / or the plurality of individual magnetic paths.

[0059] The first core 41 and the second core 42 have different magnetic permeabilities M. The magnetic permeability M1 of the first core 41 is lower than the magnetic permeability M2 of the second core 42 (M1 < M2). The magnetic permeability M1 of the first core 41 and the magnetic permeability M2 of the second core 42 are set to adjust the electromagnetic characteristics as the reactor element 40. The magnetic permeability M1 is also called the first magnetic permeability. The magnetic permeability M2 is also called the second magnetic permeability. For example, the difference between the magnetic permeability M1 of the first core 41 and the magnetic permeability M2 of the second core 42 adjusts the inductance of the reactor element 40. For example, the difference between the magnetic permeability M1 of the first core 41 and the magnetic permeability M2 of the second core 42 adjusts the saturation magnetic flux density. Note that the core 45 may have an air gap at its boundary portion.

[0060] Due to the magnetic permeability M1 and the magnetic permeability M2, the magnetic flux density of the leakage magnetic flux around the first core 41 is higher than the magnetic flux density of the leakage magnetic flux around the second core 42. As a result, there is concern about the influence of the leakage magnetic flux from the first core 41 on the function of the electrical components arranged adjacent to the first core 41. The influence can be evaluated by the frequency of the influence, the magnitude of the influence, the period of the influence, etc. The influence that the electrical components arranged adjacent to the first core 41 receive from the leakage magnetic flux from the first core 41 is also called the first influence.

[0061] On the other hand, due to the magnetic permeability M1 and the magnetic permeability M2, the magnetic flux density of the leakage magnetic flux around the second core 42 is lower than the magnetic flux density of the leakage magnetic flux around the first core 41. As a result, the influence of the leakage magnetic flux from the second core 42 on the function of the electrical components arranged adjacent to the second core 42 is relatively low. The influence that the electrical components arranged adjacent to the second core 42 receive from the leakage magnetic flux from the second core 42 is also called the second influence. Here, the term "relative" is based on the comparison between the first influence and the second influence.

[0062] The first core 41 has the minimum magnetic permeability M1 of the cores of the reactor element 40. The second core 42 has a non-minimum magnetic permeability M2 of the cores of the reactor element 40. The first core 41 can also be said to be another core having a different magnetic permeability from the second core 42. The first core 41 is also another core having a lower magnetic permeability than the second core 42.

[0063] In the following description, the current measuring unit 30, which is an example of an electrical component, is taken as an example. Those skilled in the art should understand that the current measuring unit 30 can be interpreted as an electrical component. Furthermore, those skilled in the art should understand that the current measuring function can be interpreted as the function of an electrical component. An electrical component is a component that is affected by leakage magnetic flux. An electrical component includes, for example, an inductance element, a capacitance element, or a resistance element. Furthermore, an electrical component can have various functions such as a temperature measurement function and a submersion detection function. Furthermore, an electrical component can take various mounting forms such as a semiconductor element, a surface mount element, and a through-hole mount element.

[0064] The leakage magnetic flux from the first core 41 affects the current measurement function of the current measurement unit 30 arranged adjacent to the first core 41. The effect appears in noise in the output signal from the current measurement unit 30, deviation of the output signal, etc. The leakage magnetic flux from the second core 42 affects the current measurement function of the current measurement unit 30 arranged adjacent to the second core 42. The effect on the current measurement function of the current measurement unit 30 arranged adjacent to the second core 42 is relatively smaller than the effect on the current measurement function of the current measurement unit 30 arranged adjacent to the first core 41. The relative smallness of the effect can be grasped by the smallness of noise in the output signal from the current measurement unit 30, the smallness of deviation of the output signal, etc.

[0065] FIG. 4 illustrates a boundary CB between the first core 41 and the second core 42. In the illustrated example, the boundary CB is one of the yz planes. The boundary CB is also a boundary surface between the region where the first core 41 exists and the region where the second core 42 exists. The boundary surface is defined by a plurality of connection surfaces between the first core 41 and the second core 42 and imaginary surfaces that extend radially outward from the connection surfaces. The current measurement unit 30 is disposed in the region where the second core 42 exists. In other words, the current measurement unit 30 is disposed biased toward the region where the second core 42 exists from the boundary CB. The core 45 defines the boundary CB that divides the region where the first core 41 is located and the region where the second core 42 is located. The current measurement unit 30 is disposed biased toward the region where the second core 42 is located from the boundary CB.

[0066] The offset arrangement of the current measurement unit 30 with respect to the boundary CB is called an offset relationship. From one point of view, by satisfying this offset relationship, the influence of the other core (first core 41) on the electrical component (current measurement unit 30) is suppressed.

[0067] In FIG. 4, the reactor element 40 and the current measurement unit 30 are adjacent to each other in the xy plane. The reactor element 40 and the current measurement unit 30 are disposed adjacent to each other in the x direction. In other words, the shortest distance between the reactor element 40 and the current measurement unit 30 is defined in the x direction. The x direction is also called the adjacent direction between the reactor element 40 and the current measurement unit 30. The shortest distance between the reactor element 40 and the current measurement unit 30 may be given by the distance between the surface of the core of the reactor element 40 and the surface of the sensor element 33 of the current measurement unit 30. The shortest distance between the reactor element 40 and the current measurement unit 30 is also the shortest distance of the magnetic flux path from the reactor element 40 to the current measurement unit 30.

[0068] Even when the spatial arrangement is taken into consideration, the specific reactor element 40 and the specific current measurement unit 30 are adjacent to each other. They are arranged at the shortest spatial distance. For example, the spatial distance between another reactor element 40 included in the reactor unit 7 and the specific current measurement unit 30 is longer than the above-mentioned shortest distance. For example, the spatial distance between another current measurement unit 30 included in the sensor unit 9 and the specific reactor element 40 is longer than the above-mentioned shortest distance.

[0069] The shortest distance between the first core 41 and the current measurement unit 30 is distance D1. The shortest distance between the second core 42 and the current measurement unit 30 is distance D2. Distances D1 and D2 are defined as the distance in the x direction, i.e., the distance in the adjacent direction. Distances D1 and D2 are also the distance of the magnetic flux path that the magnetic flux emitted from the reactor element 40 takes to reach the current measurement unit 30 via the shortest magnetic flux path. Distance D2 is shorter than distance D1. As a result, the influence of the reactor element 40 on the current measurement unit 30 (electrical component) is relatively small.

[0070] In the adjacent relationship, the distance D2 between the second core 42, which does not have the minimum magnetic permeability, and the electric component is shorter than the distance D1 between the other core (first core 41) and the electric component.

[0071] In this embodiment, the arrangement characterized by the distance D1 between the first core 41 and the current measurement unit 30 and the distance D2 between the second core 42 and the current measurement unit 30 is also referred to as the distance relationship in the following description. From one point of view, by satisfying this distance relationship, the influence of the other core (first core 41) on the electrical component (current measurement unit 30) is suppressed.

[0072] The second core 42 is disposed between the current measurement unit 30 and the first core 41. Moreover, the second core 42 is disposed so as to completely cover and conceal the first core 41 from the current measurement unit 30. This relationship is satisfied both in the illustrated xy plane and in the not-illustrated xz plane. For example, assume that the first core 41 and the second core 42 are seen through from the current measurement unit 30. Under this assumption, the first core 41 is completely covered and concealed by the second core 42.

[0073] In FIG. 4, a virtual line of sight VL is indicated by a broken line. The line of sight VL can reach the second core 42, but cannot reach the first core 41. When the path of the magnetic flux is assumed, the leakage magnetic flux from the first core 41 may reach the current measurement unit 30 by bypassing the second core 42. In this case, the leakage magnetic flux requires a relatively long detour path. Therefore, the influence of the detour path is small compared to the influence of passing through the linear distances D1 and D2. Therefore, the second core 42 having a relatively high magnetic permeability M2 is also a cover member that covers and hides the electric components (current measurement unit 30) from the first core 41 having a relatively low magnetic permeability M1. Therefore, in this embodiment, the second core 42 is disposed between the first core 41 and the current measurement unit 30. This prevents the first core 41 from reaching the current measurement unit 30 in a linear manner.

[0074] In the following description, the arrangement of the second core 42 between the first core 41 and the current measurement unit 30 in this embodiment is also referred to as a cover relationship. From one viewpoint, by satisfying the cover relationship, the influence of the other core (the first core 41) on the electrical component (the current measurement unit 30) is suppressed.

[0075] According to this embodiment, the leakage flux from the core (second core 42) having the magnetic permeability M2 that is not the minimum among the cores of the reactor element 40 is relatively small. Therefore, the influence of the core (second core 42) having the magnetic permeability M2 that is not the minimum among the cores of the reactor element 40 on the electric component (current measurement unit 30) is small. On the other hand, by satisfying at least one of the maldistribution relationship, the distance relationship, and the cover relationship, the influence on the electric component (current measurement unit 30) caused by the leakage flux from the core (first core 41) having the magnetic permeability M1 lower than that of the second core 42 is suppressed. In this embodiment, all of the maldistribution relationship, the distance relationship, and the cover relationship are satisfied. As a result, the influence on the electric component (current measurement unit 30) caused by the leakage flux from the reactor element 40 is suppressed.

[0076] According to the embodiment described above, in the power control device 2 in which components must be adjacent to each other, it is possible to suppress the influence of leakage flux from the reactor on electrical components other than the reactor. Moreover, the reactor element 40 can have desirable electromagnetic characteristics by including multiple cores with different magnetic permeabilities. Therefore, it is possible to suppress the influence of leakage flux on other electrical components while improving the electromagnetic characteristics of the reactor. Furthermore, it is possible to improve the characteristics and functions as a power control device.

[0077] Second embodiment This embodiment is a modification of the preceding embodiment as a basic form. In the following embodiment, the same components as those in the preceding embodiment and components providing equivalent functions are denoted by the same reference numerals. For the description of these components, please refer to the description of the preceding embodiment.

[0078] FIG. 5 shows the second embodiment. In the first embodiment, the core 45 is arranged so that the magnetic path MP extends along the xy plane. Instead, in the second embodiment, the core 245 is arranged so that the magnetic path MP extends along the xz plane. In this embodiment, the coil axis CX is also positioned so as to point toward the current measuring unit 30. In this embodiment, the uneven distribution relationship, the distance relationship, and the cover relationship are all satisfied. As a result, the same effects as those of the preceding embodiment are obtained.

[0079] Third embodiment This embodiment is a modification based on the preceding embodiment.

[0080] 6 shows a third embodiment. In the first embodiment, the core 45 is arranged so that the core axis CX is oriented toward the current measuring unit 30. Instead, in the third embodiment, the core 345 is arranged so that the core axis CX is not oriented toward the current measuring unit 30. In this embodiment, the core 345 is arranged so that the magnetic path MP extends along the xy plane. The core 345 may be arranged so that the magnetic path MP extends along the xz plane.

[0081] In this embodiment, the current measurement unit 30 is adjacent to both the first core 41 and the second core 42. However, in terms of the distances D1 and D2, the core 345 is biased toward being closer to the second core 42 than to the first core 41.

[0082] The shortest distance between the first core 41 and the current measurement unit 30 is distance D1. Distance D1 is defined as a diagonal distance that intersects with both the x direction and the y direction on the xy plane.

[0083] The core 345 is arranged so that the second core 42 and the current measurement unit 30 are adjacent to each other in the x direction. In other words, the second core 42 and the current measurement unit 30 are arranged so as to define a shortest distance D2. The distance between the second core 42 and the current measurement unit 30 is the distance D2. The distance D2 is defined as the distance in the x direction, i.e., the shortest distance in the adjacent direction.

[0084] The distance D2 is shorter than the distance D1. As a result, the influence of the reactor element 40 on the current measuring unit 30 (electrical component) is relatively small.

[0085] In this embodiment, the above-mentioned uneven distribution relationship and distance relationship are also satisfied. On the other hand, in this embodiment, the above-mentioned covering relationship is not satisfied. According to this embodiment, an effect based on the uneven distribution relationship and the distance relationship can be obtained.

[0086] Fourth embodiment This embodiment is a modification based on the preceding embodiment.

[0087] FIG. 7 shows a fourth embodiment. In the preceding embodiment, the core 45 is provided by an EE core. Instead, the core 445 is provided by an EI core. The first core 41 is an E type. The second core 42 is an I type. In this embodiment, the E type and the I type may be reversed. In this embodiment, the above-mentioned uneven distribution relationship, distance relationship, and cover relationship are all satisfied. As a result, the same action and effect as in the first embodiment can be obtained.

[0088] Fifth embodiment This embodiment is a modification based on the preceding embodiment.

[0089] FIG. 8 shows the fifth embodiment. The core 445 is arranged so that the core axis CX is oriented toward the current measurement unit 30. Instead, in the fifth embodiment, the core 545 is arranged so that the core axis CX is not oriented toward the current measurement unit 30. In other words, the core axis CX is arranged so as to avoid the current measurement unit 30. The core 545 is arranged so that a distance D1 is formed between the first core 41 and the current measurement unit 30, and a distance D2 is formed between the second core 42 and the current measurement unit 30. In this embodiment, the adjacent direction is a slightly downward diagonal direction in the figure. For this reason, the x-axis display in FIG. 8 is slightly rotated clockwise around the z-axis. In this embodiment, the above-mentioned uneven distribution relationship and distance relationship are also satisfied. Therefore, the action and effect based on the uneven distribution relationship and distance relationship can be obtained.

[0090] Sixth embodiment This embodiment is a modification based on the preceding embodiment.

[0091] 9 shows a sixth embodiment. The core 645 is provided by a UI core. The first core 41 is U-shaped. The second core 42 is I-shaped. The U-shaped and I-shaped may be reversed.

[0092] In this embodiment, a coil 46 having a plurality of coil portions is illustrated. The coil 46 has a first coil portion 647 and a second coil portion 648. The first coil portion 647 is characterized by a coil axis CX1. The second coil portion 648 is characterized by a coil axis CX2. The coil axis CX1 and the coil axis CX2 are arranged in parallel. In this embodiment, the adjacent direction is the up-down direction in the figure. Therefore, the axis display in FIG. 9 is rotated 90 degrees counterclockwise around the z direction. In this embodiment, the above-mentioned uneven distribution relationship and distance relationship are also satisfied. As a result, an action and effect based on the uneven distribution relationship and distance relationship is obtained.

[0093] Seventh embodiment This embodiment is a modification based on the preceding embodiment.

[0094] 10 shows a seventh embodiment. The core 745 is provided by a UU core. The first core 41 is U-shaped. The second core 42 is U-shaped. The first core 41 and the second core 42 are butted together in the x direction. The first core 41 and the second core 42 may be butted together in the y direction.

[0095] The first core 41 and the second core 42 are connected at two connecting parts. The boundary CB includes two connecting parts. The two connecting parts are positioned in the coil 46, i.e., in the first coil portion 647 and the second coil portion 648. In this embodiment as well, the above-described eccentric relationship and distance relationship are satisfied. As a result, an effect based on the eccentric relationship and the distance relationship is obtained.

[0096] Eighth embodiment This embodiment is a modification based on the preceding embodiment.

[0097] FIG. 11 shows an eighth embodiment. The core 845 is provided by a combination core including two I-cores in addition to a UU core. The core 845 includes a first core 41, a second core 42, and a third core 43. The first core 41 is U-shaped. The second core 42 is U-shaped. The third core 43 includes two parts disposed between the first core 41 and the second core 42. Each part of the third core 43 is provided by an I-shaped core.

[0098] The magnetic permeability M1 of the first core 41 is smaller than the magnetic permeability M2 of the second core 42 (M1 < M2). The magnetic permeability M1 of the first core 41 is smaller than the magnetic permeability M3 of the third core 43 (M1 < M3). The magnetic permeability M3 is also called the third magnetic permeability. The magnetic permeability M2 of the second core 42 is smaller than the magnetic permeability M3 of the third core 43 (M2 < M3). Therefore, the magnetic permeability M1 of the first core 41 is the smallest among the partial cores constituting the core 845. The magnetic permeability M2 of the second core 42 is the intermediate magnetic permeability among the partial cores constituting the core 845. The magnetic permeability M3 of the third core 43 is the largest among the partial cores constituting the core 845. The second core 42 has a magnetic permeability M2 that is not the minimum magnetic permeability M1 in the core 845. The third core 43 has a magnetic permeability M3 that is not the minimum magnetic permeability M1 in the core 845. Therefore, the core having a magnetic permeability that is not the minimum magnetic permeability in the core 845 is the second core 42, or the third core 43, or both the second core 42 and the third core 43.

[0099] The second core 42 and the third core 43 in the core 845 can be understood as a group of cores having magnetic permeabilities M2 and M3 that are larger than the magnetic permeability M1 in comparison with the first core 41. For this reason, the second core 42 is understood to include the third core 43 having a third magnetic permeability M3 that is larger than the second magnetic permeability M2. The third core 43 is disposed between the first core 41 and the second core 42.

[0100] A first boundary CB1 is located between the first core 41 and the third core 43. The first boundary CB1 is the boundary between the magnetic permeability M1 and the magnetic permeability M3. The magnetic permeability difference at the first boundary CB1 is relatively large. The magnetic permeability difference at the first boundary CB1 is the largest among the plurality of magnetic permeability differences in the core 845. The magnetic permeability difference at the first boundary CB1 is called the first magnetic permeability difference M13.

[0101] A second boundary CB2 is located between the second core 42 and the third core 43. The second boundary CB2 is a boundary between the magnetic permeability M2 and the magnetic permeability M3. The magnetic permeability difference at the second boundary CB2 is relatively small. The magnetic permeability difference at the second boundary CB2 is the smallest among the multiple magnetic permeability differences in the core 845. The magnetic permeability difference at the second boundary CB2 is referred to as a second magnetic permeability difference M32.

[0102] The first permeability difference M13 is greater than the second permeability difference M32. As a result, the leakage flux in the region from the first boundary CB1 where the first core 41 is located is less than the leakage flux in the region from the first boundary CB1 where the second core 42 and the third core 43 are located.

[0103] The current measurement section 30 is arranged biased toward the side of the region where the third core 43 and the second core 42 are located from the first boundary CB1. Furthermore, the current measurement section 30 is arranged biased toward the side of the region where the second core 42 is located from the second boundary CB2. As a result, the above-mentioned biased relationship is satisfied with respect to the second boundary CB2.

[0104] Alternatively, the current measurement unit 30 may be disposed between the first boundary CB1 and the second boundary CB2. In this alternative configuration, the maldistribution relationship is satisfied with respect to the first boundary CB1. From the viewpoint of suppressing the influence of leakage magnetic flux from the first core 41 to the current measurement unit 30, it is desirable that the above-mentioned maldistribution relationship is satisfied with respect to the second boundary CB2. However, even if the maldistribution relationship is merely satisfied with respect to the first boundary CB1, at least the effect of suppressing the influence caused by the leakage magnetic flux of the first core 41 is achieved.

[0105] In this embodiment, the core 845 defines a first boundary CB1 that separates an area where the first core 41 is located from an area where the third core 43 is located. The core 845 defines a second boundary CB2 that separates an area where the second core 42 is located from an area where the third core 43 is located. The current measurement unit 30 is positioned offset from the first boundary CB1 towards the area where the third core 43 is located. The current measurement unit 30 is positioned offset from the second boundary CB2 towards the area where the second core 42 is located.

[0106] A minimum distance D1 is formed between the first core 41 and the current measurement unit 30. A minimum distance D2 is formed between the second core 42 and the current measurement unit 30. The distance D2 is the distance in the x direction, i.e., the adjacent direction. A minimum distance D3 is formed between the third core 43 and the current measurement unit 30. The distances D1 and D3 are diagonal distances. The distance D1 is longer than the distance D2. The distance D1 is longer than the distance D3. The distance D2 is longer than the distance D3. The distance D1 is the longest of the multiple distances defined by the core 845. The distance D2 is the shortest of the multiple distances defined by the core 845.

[0107] Distance D1 is the distance between the first core 41, where the magnetic permeability in the core 845 is the smallest, and the current measurement unit 30. Distance D2 is the distance between the second core 42, where the magnetic permeability in the core 845 is not the smallest, and the current measurement unit 30. Distance D3 is also the distance between the third core 43, where the magnetic permeability in the core 845 is not the smallest, and the current measurement unit 30. Distance D2 is shorter than distance D1. Distance D3 is shorter than distance D1. Distance D2 is shorter than distance D3.

[0108] In this embodiment as well, the above-mentioned uneven distribution relationship and distance relationship are satisfied, and as a result, the effects based on the uneven distribution relationship and distance relationship are obtained.

[0109] Ninth embodiment The relative posture of the reactor unit 7 and the sensor unit 9 can be modified in various ways. For example, the adjacent posture illustrated in FIG. 2 can be adopted. In this adjacent posture, the reactor unit 7 and the sensor unit 9 are arranged such that the longitudinal direction (z direction) of the reactor unit 7 and the longitudinal direction (z direction) of the sensor unit 9 are parallel to each other, and the reactor unit 7 and the sensor unit 9 are overlapped in the adjacent direction (x direction). The adjacent direction (x direction) may be the lateral direction as illustrated. The lateral direction may be the horizontal direction. Alternatively, the adjacent direction (x direction) may be the vertical direction as illustrated in FIG. 9. The vertical direction may be the up-down direction. Alternatively, the adjacent direction (x direction) may be an oblique direction as illustrated in FIG. 8.

[0110] Furthermore, the reactor unit 7 and the sensor unit 9 may be arranged as in this ninth embodiment. This embodiment is a modification of the preceding embodiment as a base form.

[0111] 12 shows a ninth embodiment. In this embodiment, the longitudinal direction (x direction) of the reactor unit 7 and the longitudinal direction (y direction) of the sensor unit 9 intersect. The reactor unit 7 and the sensor unit 9 are arranged such that one end face in the longitudinal direction of the reactor unit 7 and the sensor unit 9 overlap in the adjacent direction (x direction). In this embodiment, the influence of leakage magnetic flux between the reactor element 40 arranged at one end in the longitudinal direction of the reactor unit 7 and the current measurement unit 30 of the sensor unit 9 is suppressed.

[0112] Tenth embodiment This embodiment is a modification of the preceding embodiment as a basic form, and the shield member exemplified in this embodiment can be used in combination with the other embodiments.

[0113] 13 shows a tenth embodiment. An electromagnetic shielding member that blocks linear transmission of magnetic flux is disposed between the reactor unit 7 and the sensor unit 9. The shielding member is provided by the housing 20 of the power control device 2.

[0114] The housing 20 includes an outer wall member 21 that provides an outer shell. The housing 20 includes a partition wall A22 that extends from the outer wall member 21. The partition wall A22 is integrally formed with the outer wall member 21 by a common material that is continuous with the outer wall member 21. Alternatively, the partition wall A22 may be provided by a member separate from the outer wall member 21.

[0115] The housing 20 and the partition wall A22 are electromagnetic shielding members that prevent the penetration of magnetic flux. The housing 20 and the partition wall A22 are made of a ferromagnetic material such as an electromagnetic steel plate. Alternatively, the housing 20 and the partition wall A22 may be made of a conductive material that functions as an electromagnetic shielding member by generating eddy currents. For example, the housing 20 and the partition wall A22 are made of an aluminum alloy. Alternatively, the housing 20 and the partition wall A22 may be provided by a member in which an electromagnetic steel plate is embedded in an aluminum alloy body.

[0116] A boundary CB can be assumed between the first core 41 and the second core 42. The sensor unit 9 is disposed on the side of the boundary CB where the first core 41 is located. In this case, if the leakage magnetic flux from the first core 41 were able to reach the current measurement unit 30 in a linear manner, the influence of the leakage magnetic flux would be strongly observed. However, in this embodiment, the partition wall A22 provides a shielding member, thereby suppressing the influence of the leakage magnetic flux from the first core 41.

[0117] The partition wall A22 is positioned between the reactor unit 7 and the sensor unit 9. The partition wall A22 spreads over a range that completely covers the first core 41. The partition wall A22 extends from the outer wall member 21 to a height HS that exceeds the first core 41. The height HS of the partition wall A22 is a height that exceeds the boundary CB. The height HS of the partition wall A22 in the y direction is a height at which the partition wall A22 blocks linear access between the core 45 and the current measurement unit 30. In the figure, a virtual line of sight VL directed from the current measurement unit 30 toward the core 45 is illustrated. That is, the partition wall A22 is arranged between the core 45 and the current measurement unit 30 as a magnetic shield member that covers and hides the first core 41 from the current measurement unit 30.

[0118] FIG. 13 shows a detour path of leakage magnetic flux that reaches the current measurement unit 30 from the core 45 of the reactor element 40. The length of the shortest detour path between the first core 41 and the current measurement unit 30 is distance D1. The length of the shortest detour path between the second core 42 and the current measurement unit 30 is distance D2. Distance D2 is shorter than distance D1. In this embodiment as well, the above-mentioned distance relationship is satisfied. As a result, at least the action and effect resulting from the distance relationship is obtained.

[0119] Other embodiments In the above embodiment, the current measuring unit 30 is mainly exemplified as an electrical component affected by the leakage flux from the reactor element 40. However, the electrical component affected by the leakage flux is not limited to the current measuring unit 30. The electrical component affected by the leakage flux may be a functional component that does not include a conductive member that passes a large current. In this case, various elements such as an inductance element, a control circuit, a bridge circuit, a sensor element that measures temperature, and a capacitance element may be applicable to the electrical component affected by the leakage flux. The conductive member that passes a large current may be a conductive member that passes a current as a control target of the power control device 2. The electrical component affected by the leakage flux may be a component that functions by the power supply voltage of the control system of the power control device 2. In many vehicles, for example, 12V system components or 24V system components may be applicable to the electrical component affected by the leakage flux.

[0120] In the above embodiment, the reactor element 40 having various core shapes is exemplified. The core shape of the reactor element 40 is not limited to the exemplified shape. The reactor element 40 may have a distribution of magnetic permeability in an integrally molded core formed of a continuous material. In this case, a portion of the integrally molded core having a magnetic permeability M1 corresponding to the first core 41 and a portion of a magnetic permeability M2 corresponding to the second core 42 can be found. Even if the magnetic permeability changes gradually and continuously, a boundary can be found in the center of the change area.

[0121] The reactor unit 7 may include a magnetic shielding member for reducing leakage flux to the outside. Even in such a configuration, the above-described embodiments contribute to suppressing the influence of leakage flux on electrical components.

[0122] The disclosure in this specification and drawings, etc. is not limited to the exemplified embodiments. The disclosure includes the exemplified embodiments and modifications by those skilled in the art based thereon. For example, the disclosure is not limited to the combination of parts and / or elements shown in the embodiments. The disclosure can be implemented by various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes the omission of parts and / or elements of the embodiments. The disclosure includes the substitution or combination of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.

[0123] The disclosure in the specification and drawings is not limited by the claims. The disclosure in the specification and drawings includes the technical ideas described in the claims, and extends to more diverse and broader technical ideas than the technical ideas described in the claims. Therefore, various technical ideas can be extracted from the disclosure in the specification and drawings without being bound by the claims.

[0124] (Disclosure of technical ideas) This specification discloses multiple technical ideas described in the following multiple dependent claims. Some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. Furthermore, some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. The claims described in these multiple dependent forms define multiple technical ideas.

[0125] (Technical thought 1) A power control device (2) for converting electric power, comprising: a conductive member (2a) for passing a current to be converted; a coil (46) electrically connected to the conductive member; a reactor element (40) having a core (45) for passing magnetic flux induced in the coil; and an electrical component (30) in the power control device that is affected by leakage magnetic flux from the core; The core includes at least a first core (41) having a first magnetic permeability (M1) and a second core having a second magnetic permeability (M2) greater than the first magnetic permeability, A power control device in which a first distance (D1) as a path of magnetic flux is formed between the first core and the electrical component, and a second distance (D2) as a path of magnetic flux is formed between the second core and the electrical component, and the core and the electrical component are arranged so that a distance relationship (D1>D2) in which the second distance is shorter than the first distance is satisfied.

[0126] (Technical thought 2) The power control device according to Technical Idea 1, wherein the reactor element and the electrical component are arranged adjacent to each other in the power control device.

[0127] (Technical Thought 3) The core defines a boundary (CB, CB1) that divides an area in which the first core is located and an area in which the second core is located, The power control device according to Technical Idea 1 or 2, wherein the electrical components are biasedly arranged on the side of the region where the second core is located, away from the boundary.

[0128] (Technical Thought 4) A power control device according to any one of technical ideas 1 to 3, wherein the second core is arranged between the first core and the electrical component, and a straight line from the first core to the electrical component is prevented.

[0129] (Technical Thought 5) The power control device according to any one of Technical Ideas 1 to 4, wherein the second core includes a third core (43) having a third permeability greater than the second permeability.

[0130] (Technical Thought 6) The power control device according to Technical Concept 5, wherein the third core is disposed between the first core and the second core.

[0131] (Technical Thought 7) the core defines a first boundary (CB1) that separates an area in which the first core is located from an area in which the third core is located, and a second boundary (CB2) that separates an area in which the second core is located from an area in which the third core is located, A power control device as described in technical idea 6, wherein the electrical components are biased toward the side of the area where the third core is located, rather than the first boundary, or toward the side of the area where the second core is located, rather than the second boundary.

[0132] (Technical Thought 8) A power control device according to any one of technical ideas 1 to 7, in which a magnetic shielding member (A22) is arranged between the core and the electrical component to cover and hide the first core from the electrical component.

[0133] (Technical Thought 9) The power control device according to any one of technical ideas 1 to 8, wherein the electrical component is a circuit (34a) affected by the leakage magnetic flux, or a magnetic body (33a) affected by the leakage magnetic flux, or includes both the circuit and the magnetic body.

[0134] (Technical Thought 10) The power control device according to any one of Technical Ideas 1 to 9, wherein the electrical component is an electromagnetic current measuring unit (30) that detects magnetic flux resulting from a current flowing through the conductive member. [Explanation of symbols]

[0135] 1 Power system, 2 Power control device, 3 Battery, 4 Rotating electric machine, 5 Converter, 6 Inverter, 7 Reactor unit, 8 Capacitor unit, 9 Sensor unit, 10 Control circuit, 11 Heat dissipation module, 12 Switch module, 20 Housing, 21 Outer wall member, A22 Partition member, 30 Current measurement unit, 31 Housing, 32 Conductive member, 33 Sensor element, 34 Circuit board, 35 Shield member, 36 First shield member, 37 Second shield member, 40 Reactor element, 41 First core, 42 Second core, 43 Third core, 45, 245, 345, 445, 545, 645, 745, 845 Core, 46 Coil, 647 First coil portion, 648 Second coil portion, CB boundary, CB1 first boundary, CB2 second boundary, CX, CX1, CX2 coil axis, D1, D2, D3 distance, Sf internal flux, Nf external flux, MP flux path, HS height, VL line of sight.

Claims

1. In a power control device (2) that converts power, A conductive member (2a) for passing the current to be converted; a reactor element (40) having a coil (46) electrically connected to the conductive member and a core (45) through which magnetic flux induced in the coil passes; an electrical component (30) in the power control device that is affected by leakage magnetic flux from the core; The core is A first core (41) having a first magnetic permeability (M1); and a second core having a second permeability (M2) greater than the first permeability, A power control device in which a first distance (D1) as a magnetic flux path is formed between the first core and the electrical component, and a second distance (D2) as a magnetic flux path is formed between the second core and the electrical component, and the core and the electrical component are arranged so that a distance relationship (D1 > D2) in which the second distance is shorter than the first distance is satisfied.

2. The power control device according to claim 1 , wherein the reactor element and the electrical component are disposed adjacent to each other in the power control device.

3. The core defines a boundary (CB, CB1) that divides an area in which the first core is located and an area in which the second core is located, 3. The power control device according to claim 1, wherein the electrical components are arranged offset from the boundary toward the side of the region in which the second core is located.

4. 3. The power control device according to claim 1, wherein the second core is disposed between the first core and the electrical component, and a straight line from the first core to the electrical component is prevented.

5. The power control device according to claim 1 or 2, wherein the second core includes a third core (43) having a third permeability greater than the second permeability.

6. The power control device according to claim 5 , wherein the third core is disposed between the first core and the second core.

7. The core is a first boundary (CB1) that separates a region in which the first core is located from a region in which the third core is located; a second boundary (CB2) that divides a region in which the second core is located from a region in which the third core is located; The power control device according to claim 6 , wherein the electrical components are arranged biased toward the side of the region in which the third core is located from the first boundary, or toward the side of the region in which the second core is located from the second boundary.

8. 3. The power control device according to claim 1, further comprising a magnetic shield member (A22) disposed between the core and the electric components to cover and hide the first core from the electric components.

9. The electrical component is A circuit (34a) that is affected by the leakage magnetic flux, or A magnetic body (33a) that is affected by the leakage magnetic flux, or The power control device according to claim 1 or 2, comprising both the circuit and the magnetic body.

10. 3. The power control device according to claim 1, wherein the electrical component is an electromagnetic current measuring unit (30) that detects a magnetic flux resulting from a current flowing through the conductive member.

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