Electric device, and power conversion device

Abstract

To provide an electric device which achieves breakage prevention of a weld part and improvement of heat radiation performance.SOLUTION: An electric device includes a plurality of capacitor elements having a connection terminal, a conductive bus bar connected to the connection terminal, a mold bus bar sealing the bus bar with an insulative resin member, a housing including a capacitor storage part where at least a part of the plurality of capacitor elements is stored, and a sealing member which is filled between the plurality of capacitor elements and the inner wall of the capacitor storage part, and fixes the plurality of capacitor elements, wherein the mold bus bar is arranged so as to face the plurality of capacitor elements and the sealing member, the mold bus bar has a projection part which is a part of the resin member and projects to the sealing member between the plurality of capacitor elements, and at least a part of the projection part is immersed in the sealing member.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an electrical device and an electric quantity conversion device.

Background Art

[0002] In Patent Document 1 below, for the purpose of achieving both miniaturization of a power conversion device and improvement of cooling efficiency, a molded bus bar that is welded to a capacitor immersed in a potting resin has a configuration in which a part thereof is similarly immersed in the potting resin and fixed.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the technique described in Patent Document 1, although a part of the molded bus bar is arranged along the wall of the housing in which the flow path is formed for heat dissipation purposes, in this configuration, from the viewpoints of shock resistance and vibration resistance performance, the welded connection part between the molded bus bar and the capacitor may break.

Means for Solving the Problems

[0005] The electrical device includes a plurality of capacitor elements having connection terminals, a conductive bus bar connected to the connection terminals, a molded bus bar in which the bus bar is sealed with an insulating resin member, a housing provided with a capacitor housing portion for housing at least a part of the plurality of capacitor elements, and a sealing member filled between the plurality of capacitor elements and the inner wall of the capacitor housing portion for fixing the plurality of capacitor elements. The molded bus bar is disposed to face the plurality of capacitor elements and the sealing member. The molded bus bar is a part of the resin member and has a protruding portion that protrudes toward the sealing member between the plurality of capacitor elements, and at least a part of the protruding portion is immersed in the sealing member.

Advantages of the Invention

[0006] According to the present invention, it is possible to provide an electrical device that realizes prevention of breakage of a welded portion and improvement of heat dissipation performance.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Mode for Carrying Out the Invention

[0008] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following description and drawings are examples for explaining the present invention, and for the sake of clarity of explanation, appropriate omissions and simplifications have been made. The present invention can also be implemented in various other forms. Unless otherwise particularly limited, each component may be singular or plural.

[0009] The positions, sizes, shapes, ranges, etc. of the components shown in the drawings may not represent the actual positions, sizes, shapes, ranges, etc. in order to facilitate the understanding of the invention. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, ranges, etc. disclosed in the drawings.

[0010] (One Embodiment and Overall Configuration) (Figs. 1 and 2) Fig. 2(a) is an elevation view of the electric device 100 in Fig. 1 as viewed from the outside of the housing 3, and Fig. 2(b) is an elevation view of the electric device 100 as viewed from the left - right direction of Fig. 2(a). The electric device 100 is a capacitor module used in an in - vehicle power conversion device, and includes a plurality of capacitor elements 1, a molded busbar 2, a housing 3, and a potting resin 4. The molded busbar 2 is disposed opposite to the plurality of capacitor elements 1 and the potting resin 4 within the housing 3. The molded busbar 2 has a protruding portion 210. At least a part of the protruding portion 210 is immersed in the potting resin 4.

[0011] (Fig. 3) The plurality of capacitor elements 1 are smoothing capacitors for smoothing DC power, and each has a connection terminal 101. The housing 3 has a capacitor housing portion 301. At least a part of the plurality of capacitor elements 1 is housed in the capacitor housing portion 301. The space between the inner wall of the capacitor housing portion 301 and the plurality of capacitor elements 1 is filled with the potting resin 4 as a sealing member. The potting resin 4 has the role of fixing the capacitor elements 1 and dissipating the heat of the capacitor elements 1.

[0012] The molded busbar 2 has a conductive positive busbar 201 and a negative busbar 202, and the positive busbar 201 and the negative busbar 202 are sealed with an insulating resin member 203. In the molded busbar 2, the positive busbar 201 and the negative busbar 202 are electrically connected to the connection terminals 101 of the capacitor elements 1 by means such as welding. Note that the molded busbar 2 may integrally include other busbars and members other than the positive busbar 201 and the negative busbar 202.

[0013] The protruding portion 210 is formed of the resin member 203 that seals the positive bus bar 201 and the negative bus bar 202 in the molded bus bar 2, and protrudes from the molded bus bar 2 toward the potting resin 4 filled between the capacitor elements 1 arranged in the capacitor housing portion 301. In this way, the protruding portion 210 is made of the same material as the resin member 203, and is formed integrally with the molded bus bar 2, thereby suppressing an increase in the number of components and contributing to miniaturization and cost reduction. Note that although the protruding portion 210 is formed integrally with the molded bus bar 2, it may be formed separately from the portion that seals the positive bus bar 201 and the negative bus bar 202.

[0014] The molded busbar 2 has a plurality of fixing portions 230 on the outer periphery for fixing the molded busbar 2 to the housing 3. By forming the fixing portions 230 on the outer periphery of the molded busbar 2, the area in which the positive busbar 201 and the negative busbar 202 face each other can be increased on the molded busbar 2, and therefore the inductance can be kept small.

[0015] In this way, by immersing the protruding portion 210 in the potting resin 4, the immersed portion becomes the fixing portion of the molded busbar 2, thereby improving the holding force of the molded busbar 2 and improving the earthquake resistance and resistance to external forces. Also, by increasing the fixing portions of the molded busbar 2, the fixing strength of the molded busbar 2 is increased, and the stress and strain generated between the molded busbar 2 and the protruding portion 210 can be dispersed, no stress concentration portion is generated, the load on the welded portion that is welded to the capacitor element 1 is reduced, and breakage of the welded portion can be prevented.

[0016] Furthermore, since the fixation of the molded busbar 2 is improved in the molded busbar 2, it is not necessary to increase the number of fixing portions 230 in response to an increase in the number of capacitor elements 1. Furthermore, the number of heat dissipation paths of the molded busbar 2 can be increased, thereby improving the heat dissipation performance.

[0017] As shown in FIG. 1, the protruding portion 210 is formed such that the length protruding from the mold bus bar 2 is longer than the distance from the mold bus bar 2 to the central position of the capacitor element 1 in the capacitor element 1. Thereby, the fixity of the mold bus bar 2 can be ensured, and the holding force of the mold bus bar 2 can be improved. In addition, the load on the welding connection portion connected to the capacitor element 1 can be reduced, contributing to the improvement of seismic performance and external force resistance.

[0018] In addition, when further improving the holding force of the mold bus bar 2, the protruding portion 210 may be formed longer and immersed in the potting resin 4, or the protruding portion 210 may be immersed in the potting resin 4 up to the root. Further, even when the length of the protruding portion 210 protruding from the mold bus bar 2 is formed shorter than the distance from the mold bus bar 2 to the central position of the capacitor element 1, it is sufficient that the protruding portion 210 is immersed in the potting resin 4.

[0019] (FIG. 4) The protruding portions 210 are formed in a lattice pattern when the mold bus bar 2 is viewed in a plane. As shown in FIG. 3 described above, the six capacitor elements 1 accommodated in the capacitor accommodating portion 301 are arranged in two rows in the short side direction and three rows in the long side direction of the capacitor accommodating portion 301. When the mold bus bar 2 is installed on the housing 3, lattice-shaped protruding portions 210 are arranged between the arrangements of the six capacitor elements 1. Thereby, the plurality of capacitor elements 1 accommodated in the capacitor accommodating portion 301 are each partitioned by the protruding portion 210.

[0020] In this way, by adopting the protruding portion 210 having a shape adapted to the arrangement of the capacitor elements 1 in the capacitor accommodating portion 301, the adjacent capacitor elements 1 can be separated by the insulating protruding portion 210, and the insulation between the capacitor elements 1 can be improved. In addition, the mold bus bar 2 can be easily fixed and positioned with respect to the housing 3.

[0021] In addition, in the capacitor elements 1 adjacent to each other, the respective connection terminals 101 face each other with the protruding portion 210 interposed therebetween. However, since they can be insulated from each other by the insulating protruding portion 210, the distance between the connection terminals 101 can be arranged closer to each other.

[0022] Note that it is not necessary for the protruding portion 210 to be formed in all the gaps between the plurality of capacitor elements 1, and it may be configured such that the protruding portion 210 is provided in at least a part of the gaps. Further, as the shape of the protruding portion 210, in FIG. 4, a wall plate shape along the gap between the capacitor elements 1 is illustrated, but it is not limited thereto, and it may be configured in such a manner that a plurality of columnar (pile-shaped) protruding portions 210 are provided along the gap between the capacitor elements 1, or other shapes may be used.

[0023] (Modification example) (FIG. 5) The protruding portion 210 has uneven portions 220 on its side surface. Thereby, the adhesion range between the protruding portion 210 and the potting resin 4 can be increased, and the adhesion between the potting resin 4 and the protruding portion 210 is enhanced, so that the holding force of the molded bus bar 2 can be further improved. Further, thereby, the load on the welding portion connected to the capacitor element 1 in the molded bus bar 2 can be reduced, leading to an improvement in seismic resistance performance and external force resistance.

[0024] Note that the shape of the uneven portion 220 is not limited, and includes, for example, a wedge shape, a wave shape, etc. Also, the size of the uneven shape of the uneven portion 220 is not limited, and it may simply include a state where the surface shape of the side surface of the protruding portion 210 is rough.

[0025] As an application destination of the configuration of the electric device 100 of the present invention, it is particularly suitable for an in-vehicle power conversion device with high requirements for seismic resistance, but it can also be applied to other devices.

[0026] According to the embodiment of the present invention described above, the following operational effects are achieved.

[0027] (1) The electrical device 100 includes a plurality of capacitor elements 1 having connection terminals 101, conductive bus bars 201 and 202 connected to the connection terminals 101, a molded bus bar 2 in which the bus bars 201 and 202 are sealed with an insulating resin member 203, a housing 3 provided with a capacitor housing portion 301 in which at least a part of the plurality of capacitor elements 1 is housed, and a sealing member 4 filled between the plurality of capacitor elements 1 and the inner wall of the capacitor housing portion 301 to fix the plurality of capacitor elements 1. The molded bus bar 2 is disposed to face the plurality of capacitor elements 1 and the sealing member 4. The molded bus bar 2 is a part of the resin member 203 and has a protruding portion 210 that protrudes toward the sealing member 4 between the plurality of capacitor elements 1. At least a part of the protruding portion 210 is immersed in the sealing member 4. By doing so, it is possible to provide the electrical device 100 that realizes prevention of breakage of the welded portion and improvement of heat dissipation performance.

[0028] (2) The protruding portion 210 is formed in a lattice shape when the molded bus bar 2 is viewed in a plane, and the plurality of capacitor elements 1 housed in the capacitor housing portion 301 are each partitioned by the protruding portion 210. By doing so, the insulation between the capacitor elements 1 is improved, and the fixing and positioning of the molded bus bar 2 are facilitated.

[0029] (3) The protruding portion 210 has uneven portions 220 on its side surface. By doing so, the holding force of the molded bus bar 2 is improved.

[0030] (4) The protruding portion 210 is integrally formed with the molded bus bar 2. By doing so, it contributes to miniaturization and cost reduction.

[0031] (5) The length of the protruding portion 210 protruding from the molded bus bar 2 is formed longer than the distance from the molded bus bar 2 to the central position of the capacitor element 1 in the capacitor element 1. By doing so, the holding force of the molded bus bar 2 is improved.

[0032] (6) Among the plurality of capacitor elements 1 that are adjacent to each other, the connection terminals 101 of the respective capacitor elements 1 face each other with the protruding portion 210 interposed therebetween. By doing so, the distance between the connection terminals 101 can be arranged to be close to each other.

[0033] (7) The molded bus bar 2 has a fixing portion 230 for fixing the molded bus bar 2 to the housing 3 on the outer peripheral portion. By doing so, the inductance in the molded bus bar 2 can be suppressed to be small.

[0034] (8) A power conversion device including the electrical device 100 is adopted. By doing so, a power conversion device that realizes prevention of breakage of the welded portion and improvement of heat dissipation performance can be provided.

[0035] Note that the present invention is not limited to the above-described embodiments, and various modifications and other configurations can be combined without departing from the gist thereof. Further, the present invention is not limited to those having all the configurations described in the above embodiments, and also includes those in which a part of the configuration is deleted.

Explanation of Reference Numerals

[0036] 1 Capacitor element 2 Molded bus bar 3 Housing 4 Potting resin 100 Electrical device 101 Connection terminal 201 Positive bus bar 202 Negative bus bar 203 Resin member 210 Protruding portion 220 Concavo-convex portion 230 Fixing portion 301 Capacitor housing portion

Claims

1. A plurality of capacitor elements having connection terminals, A conductive bus bar connected to the connection terminals, A molded bus bar in which the bus bar is sealed with an insulating resin member, A housing provided with a capacitor housing portion for housing at least a part of the plurality of capacitor elements, A sealing member filled between the plurality of capacitor elements and the inner wall of the capacitor housing portion to fix the plurality of capacitor elements, The molded bus bar is disposed to face the plurality of capacitor elements and the sealing member, The molded bus bar is a part of the resin member and has a protruding portion that protrudes toward the sealing member between the plurality of capacitor elements, At least a part of the protruding portion is immersed in the sealing member Electrical device.

2. The electrical device according to claim 1, The protruding portion is formed in a lattice shape when the molded bus bar is viewed in a plane, The plurality of capacitor elements housed in the capacitor housing portion are respectively partitioned by the protruding portion Electrical device.

3. The electrical device according to claim 1, The protruding portion has uneven portions on its side surface Electrical device.

4. The electrical device according to claim 1, The protruding portion is integrally formed with the molded bus bar Electrical device.

5. The electrical device according to claim 1, The length of the protruding portion protruding from the molded bus bar is formed longer than the distance from the molded bus bar to the central position of the capacitor element in the capacitor element Electrical device.

6. The electrical device according to claim 1, Among the plurality of capacitor elements adjacent to each other, the respective connection terminals face each other with the protruding portion interposed therebetween Electrical device.

7. The electrical device according to claim 1, The molded bus bar has a fixing portion for fixing the molded bus bar to the housing at its outer peripheral portion Electrical device.

8. A power conversion device comprising the electrical device according to any one of claims 1 to 7 Power conversion device.

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