Power module, power module exterior wall resin, and power module manufacturing method
The power module design integrates a magnetic detection unit within an outer wall resin with a complementary insertion hole, addressing alignment and exposure issues for improved performance and reliability.
Patent Information
- Application Number
- JP2024193713
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-01-19
- Filing Date
- 2024-11-05
- Publication Date
- 2025-08-01
AI Technical Summary
Existing power modules lack efficient integration of magnetic detection units with bus bars, leading to potential exposure and misalignment issues, which can affect performance and reliability.
A power module design incorporating a bus bar, magnetic detection unit, and an outer wall resin with a complementary insertion hole that securely houses the magnetic detection unit, ensuring precise alignment and protection.
The solution enhances the integration and protection of magnetic detection units within power modules, preventing exposure and misalignment, thereby improving performance and reliability.
Smart Images
Figure 2025113157000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a power module, an outer wall resin for a power module, and a method for manufacturing a power module.
Background Art
[0002] Patent Document 1 discloses "an electric device that can contribute to simplification and miniaturization of the configuration of an electric device and further to a shielding effect". Patent Document 2 discloses "a power module provided with a sensing unit". [Prior Art Documents] [Patent Documents] [Patent Document 1] Japanese Patent Application Laid-Open No. 2023-138260 [Patent Document 2] US Patent Publication No. 2022 / 0262773
Summary of the Invention
[0003] In a first aspect of the present invention, a power module is provided. The power module includes a bus bar, a magnetic detection unit, and an outer wall resin. The outer wall resin has an insertion hole into which the magnetic detection unit is inserted. When viewed from the insertion direction of the magnetic detection unit, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit.
[0004] The magnetic detection unit may include a magnetic detection element and a substrate to which the magnetic detection element is fixed. A plane of the substrate provided with the magnetic detection element may be orthogonal to the insertion direction.
[0005] The magnetic detection unit may include a magnetic detection element and a substrate to which the magnetic detection element is fixed. A plane of the substrate provided with the magnetic detection element may be parallel to the insertion direction.
[0006] The outer wall resin may cover a part of the bus bar.
[0007] In the power module, three of the bus bars may be arranged side by side in a direction orthogonal to the extending direction of the bus bar.
[0008] The above power module may have one of the above busbars.
[0009] The magnetic detection unit may include a magnetic detection element, an element portion to which the magnetic detection element is fixed, and a substrate to which the element portion is fixed. The outer wall resin may have a positioning portion in contact with the element portion on a part of the wall surface forming the insertion hole.
[0010] The magnetic detection unit may be inserted into the insertion hole and may have a gap between the wall surface of the outer wall resin forming the insertion hole and the side surface of the magnetic detection unit.
[0011] The magnetic detection unit may be fixed in the insertion hole in a state where there is a gap between the wall surface of the outer wall resin forming the insertion hole and the side surface of the magnetic detection unit.
[0012] The magnetic detection unit may be inserted into the insertion hole, and the lower surface of the wall surface of the outer wall resin forming the insertion hole and the lower end portion of the magnetic detection unit may be in contact.
[0013] The magnetic detection unit may include a magnetic detection element and a substrate to which the magnetic detection element is fixed. The magnetic detection unit may be inserted into the insertion hole, and a part of the wall surface of the outer wall resin forming the insertion hole and the lower surface of the substrate may be in contact.
[0014] The outer wall resin may have a first portion surrounding at least a part of the busbar and a second portion provided with the insertion hole.
[0015] The busbar may not be exposed in the insertion hole.
[0016] The insertion hole may have a shape complementary to the outer shape of the magnetic detection unit with respect to a plane orthogonal to the insertion direction.
[0017] In a second aspect of the present invention, an outer wall resin for a power module is provided. The outer wall resin for the power module is an outer wall resin for a power module having a bus bar and a magnetic detection unit, and has an insertion hole into which the magnetic detection unit is inserted. When viewed from the insertion direction of the magnetic detection unit, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit.
[0018] In a third aspect of the present invention, a method for manufacturing a power module is provided. The method for manufacturing a power module is a method for manufacturing a power module having a bus bar and a magnetic detection unit, and includes a step of resin-molding the bus bar to form an outer wall resin having an insertion hole into which the magnetic detection unit is inserted, and a step of inserting the magnetic detection unit into the insertion hole. When viewed from the insertion direction in which the magnetic detection unit is inserted into the outer wall resin, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit.
[0019] Note that the above summary of the invention does not list all the features of the present invention. Also, sub-combinations of these feature groups can also be inventions.
Brief Description of the Drawings
[0020]
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Embodiments for Carrying Out the Invention
[0021] Hereinafter, the present invention will be described through embodiments of the invention. However, the following embodiments do not limit the invention according to the claims. Also, not all combinations of features described in the embodiments are essential for the solution means of the invention.
[0022] FIG. 1 is a perspective view showing an example of the schematic configuration of the power module 101 in the first embodiment. An xyz coordinate system is shown in each figure. As shown in FIG. 1, the power module 101 includes an outer wall resin 10, a bus bar 20 protruding in the -y direction, a magnetic detection unit 30, a protective resin 40, and two other bus bars 20c protruding in the +y direction. The power module 101 in the first embodiment is a single-phase power module. The outer wall resin 10 forms the outer wall of the power module 101 and is formed to cover the power module 101. Note that the bus bar 20 is a conductor used for the inflow and outflow of current from the outside and is also used as a conductor for measuring current. That is, when the bus bar 20 is incorporated into the power module 101, it may be a conductor through which the current to be measured flows. Also, the bus bar 20c is used as a conductor for connecting to a battery. The protective resin 40 is provided to protect each component inside the power module 101. As the protective resin 40, for example, a gel-like resin such as a silicone resin or an epoxy resin is used.
[0023] FIG. 2 is a perspective view showing an example of the schematic configuration of the bus bar 20 in the first embodiment. The bus bar 20 has two main body parts 21, 22, two current paths 23, 24, and a through hole 25. Note that the bus bar 20 shown in FIG. 2 is also used in the second, third, and fourth embodiments.
[0024] As shown in FIG. 2, the two main body parts 21, 22 are arranged side by side in the y direction. The two current paths 23, 24 are arranged between the two main body x parts 21, 22 and extend parallel to each other, connecting the two main body parts 21, 22. A through hole 25 is arranged between the two current paths 23, 24. In each of the two current paths 23, 24, the current to be measured flows in the same direction. In this embodiment, the two current paths 23, 24 are conductors having a rectangular cross-sectional shape and extending linearly. Note that the cross-sectional shape of the two current paths 23, 24 may be any shape such as circular or elliptical. Similarly, although the shape of the main body part 22 is rectangular in the drawing, it may be freely deformed according to the structure of the power module 101.
[0025] Figure 3 is a perspective view showing an example of the schematic configuration of the magnetic detection unit 30 in the first embodiment. The magnetic detection unit 30 includes a substrate 31, an element portion 32, and connection terminals 33. In the element portion 32, for example, two magnetic detection elements 34 and 35 are molded and fixed with resin. The element portion 32 may be, for example, a magnetic sensor. Note that the number of magnetic detection elements included in the element portion 32 is not limited to two. For example, the element portion 32 may have only one magnetic detection element, or may have more than two magnetic detection elements. Also, the number, arrangement, etc. of the magnetic detection elements are not limited to the illustrated form.
[0026] When the element portion 32 has two magnetic detection elements 34 and 35, the two magnetic detection elements 34 and 35 respectively detect the strength of the magnetic field generated on each magnetic sensitive surface by the measured current flowing in the y direction through the two current paths 23 and 24, and output detection signals corresponding to the detection intensities respectively detected by the two magnetic detection elements 34 and 35. The two magnetic detection elements 34 and 35 are respectively arranged such that the magnetic fields generated by the measured currents flowing in the same direction through the two current paths 23 and 24 penetrate the magnetic sensitive surface for detection. A plurality of magnetic detection elements may be arranged for purposes such as suppressing external magnetic fields, increasing output signals, and offset cancellation.
[0027] When the element portion 32 is a magnetic sensor, it may include one or more magnetic detection elements, a signal processing IC that processes an output signal based on the detection signals output from the magnetic detection elements, an output terminal that outputs the output signal, and a package that seals a part of the magnetic detection elements, the signal processing IC, and the output terminal.
[0028] As the magnetic detection element, a magnetoelectric conversion element can be used. As the magnetoelectric conversion element, for example, a Hall element that can obtain a detection signal proportional to the magnitude of the magnetic flux density can be used. In addition to the Hall element, a magnetoresistive element, a magnetic impedance element, etc. may be used as the magnetoelectric conversion element. Furthermore, as long as the detection signal is uniquely determined with respect to the applied magnetic flux density, such as a magnetic sensor IC combining these magnetoelectric conversion elements and an IC processing circuit, it can be used as the magnetic detection element. When a plurality of two magnetic detection elements are arranged, 34 and 35 may have different shapes and sizes.
[0029] FIG. 4 is an exploded perspective view showing an example of the schematic configuration of the power module 101 in the first embodiment. In FIG. 4, only the configuration on the front side (-y direction side) of the power module 101 is drawn, and the configuration on the back side (+y direction side), such as the protective resin 40, is not drawn. As shown in FIG. 4, the outer wall resin 10 of the power module 101 has an insertion hole 11 into which the magnetic detection unit 30 is inserted. The surface of the substrate 31 provided with the element portion 32 is parallel to the insertion direction (z direction) of the magnetic detection unit 30.
[0030] FIG. 5 is a first example of a top view showing the schematic configuration of the insertion hole 11 in the first embodiment. FIG. 5 shows a view when seen from the insertion direction (z direction) of the magnetic detection unit 30. As shown in FIG. 5, when the insertion hole 11 is viewed from the insertion direction of the magnetic detection unit 30, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection unit 30. The "shape corresponding to the outer shape" of the magnetic detection unit 30 means a shape corresponding to the shape of the projection plane of the magnetic detection unit 30 in the z direction. It can also be said that these are complementary shapes in the direction orthogonal to the insertion direction. For example, when the shape of the projection plane of the magnetic detection unit 30 in the z direction is a right convex shape as shown in FIG. 5, the shape of the insertion hole 11 is a right convex shape. Furthermore, the "corresponding shape" means a shape that is not the same shape but one size larger, whereby the magnetic detection unit 30 can be inserted into the insertion hole 11.
[0031] FIG. 6 is a first example of a side cross-sectional view showing the schematic configuration of the insertion hole 11 in the first embodiment. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 is in contact with the lower end portion of the substrate 31 of the magnetic detection unit 30, whereby the magnetic detection unit 30 is positioned in the vertical direction. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed in the insertion hole 11 by the adhesive 12. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the power module 101 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30. The current paths 23 and 24 of the bus bar 20 are arranged in the outer wall resin 10. That is, the bus bar 20a is not exposed on the surface of the wall surface of the outer wall resin 10 forming the insertion hole 11.
[0032] FIG. 7 is a second example of a side cross-sectional view showing the schematic configuration of the insertion hole 11 in the first embodiment. A part of the wall surface of the outer wall resin 10 forming the insertion hole 11 has a positioning portion 13 that contacts the element portion 32 to which the magnetic detection elements 34 and 35 of the magnetic detection unit 30 are fixed. The positioning portion 13 is formed based on the shapes of the substrate 31 and the element portion 32, and in a state where the magnetic detection unit 30 is inserted into the insertion hole 11, it is a portion that protrudes toward the center of the insertion hole 11 and contacts the element portion 32 among the wall surfaces of the outer wall resin 10 forming the insertion hole 11. That is, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 is in contact with the lower end portion of the substrate 31 of the magnetic detection unit 30, and the lower portion of the element portion 32 is in contact with the positioning portion 13. Thereby, the magnetic detection unit 30 is positioned in the vertical direction. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed in the insertion hole 11 by the adhesive 12. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the power module 101 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30. The current paths 23 and 24 of the bus bar 20 are arranged in the outer wall resin 10. That is, the bus bar 20a is not exposed on the surface of the wall surface of the outer wall resin forming the insertion hole 11.
[0033] FIG. 8 is a perspective view showing an example of the schematic configuration of the power module 102 in the second embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. As shown in FIG. 8, the power module 102 includes an outer wall resin 10, a bus bar 20 protruding in the -y direction, a magnetic detection unit 30a, a protective resin 40, and another bus bar 20c protruding in the +y direction. The power module 102 in the second embodiment is a single-phase power module.
[0034] FIG. 9 is a perspective view showing an example of the schematic configuration of the magnetic detection unit 30a in the second embodiment. The magnetic detection unit 30a includes a substrate 31, an element portion 32, and connection terminals 33. In the element portion 32, for example, two magnetic detection elements 34, 35 are molded and fixed with resin. The element portion 32 may be, for example, a magnetic sensor. Different from the magnetic detection unit 30 in the first embodiment, the substrate 31 of the magnetic detection unit 30a in the second embodiment is a plane parallel to the xy plane. The element portion 32 is provided on the lower surface (-z direction side surface) of the substrate 31.
[0035] FIG. 10 is an exploded perspective view showing an example of the schematic configuration of the power module 102 in the second embodiment. As shown in FIG. 10, the outer wall resin 10 of the power module 102 has an insertion hole 11 into which the magnetic detection unit 30a is inserted. In FIG. 10, only the configuration on the front side (-y direction side) of the power module 102 is depicted, and the protective resin 40 and the like on the back side (+y direction side) are not depicted. The (xy plane) including the element portion 32 of the substrate 31 is orthogonal to the insertion direction (z direction) of the magnetic detection unit 30a.
[0036] FIG. 11 is a top view showing a schematic configuration of the insertion hole 11 in the second embodiment. FIG. 11 shows a view when seen from the insertion direction (z direction) of the magnetic detection unit 30a. As shown in FIG. 11, when seen from the insertion direction (z direction) of the magnetic detection unit 30a, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection unit 30a. That is, since the shape of the projection plane in the z direction of the magnetic detection unit 30a is rectangular, the shape of the insertion hole 11 when seen from the z direction is rectangular. In the central portion of the insertion hole 11, a depression 15 is provided in which an element portion 32 protruding in the -z direction is arranged.
[0037] FIG. 12 is a side cross-sectional view showing a schematic configuration of the insertion hole 11 in the second embodiment. As shown in FIG. 12, when seen from the y direction as shown in FIG. 12, since the outer shape of the magnetic detection unit 30a is a downward convex shape, the shape of the insertion hole 11 is a downward convex shape. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, a part of the wall surface of the outer wall resin 10 forming the insertion hole 11 is in contact with the lower end portion of the substrate 31 of the magnetic detection unit 30a. Thereby, the magnetic detection unit 30a is positioned in the vertical direction. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30a is fixed in the insertion hole 11 by an adhesive 12. Note that the power module 102 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the substrate 31 of the magnetic detection unit 30a when the magnetic detection unit 30a is inserted into the insertion hole 11. Also, the current paths 23, 24 of the bus bar 20 are arranged in the outer wall resin 10. The lower surface of the element portion 32 may be in contact with the wall surface of the outer wall resin 10 forming the depression 15, or there may be a gap between the element portion 32 and the wall surface of the outer wall resin 10 forming the depression 15.
[0038] FIG. 13 is a perspective view showing an example of a schematic configuration of the power module 103 in the third embodiment. In the following description, the same reference numerals are given to the parts common to the power module 101 in the first embodiment, and the description thereof is omitted. The power module 103 in the third embodiment is a power module for a three-phase motor, includes three bus bars 20, and the three bus bars 20 are arranged side by side in the x direction.
[0039] The three busbars 20 respectively correspond to the U-phase, V-phase, and W-phase in three-phase alternating current.
[0040] As shown in FIG. 13, the power module 103 includes an outer wall resin 10, three busbars 20 protruding in the -y direction, three magnetic detection parts 30, a protective resin 40, and another busbar 20c protruding in the +y direction. Each of the three magnetic detection parts 30 is the same as the magnetic detection part 30 shown in FIG. 3, and each of the three busbars 20 is the same as the busbar 20 shown in FIG. 2. The outer wall resin 10 of the power module 103 has three insertion holes 11 into which the three magnetic detection parts 30 are inserted. When viewed from the insertion direction of the three magnetic detection parts 30, the three insertion holes 11 have a shape corresponding to the outer shape of the three magnetic detection parts 30. The shape of the three insertion holes 11 is the same as the shape shown in FIGS. 5 and 6.
[0041] FIG. 14 is a perspective view showing an example of the schematic configuration of the power module 104 in the fourth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. The power module 104 in the fourth embodiment is a power module for a three-phase motor, includes three busbars 20 in the first embodiment, and the three busbars 20 are arranged side by side in the x direction.
[0042] The three busbars 20 respectively correspond to the U-phase, V-phase, and W-phase in three-phase alternating current.
[0043] As shown in FIG. 14, the power module 104 includes an outer wall resin 10, three bus bars 20 protruding in the -y direction, three magnetic detection units 30a, a protective resin 40, and another bus bar 20c protruding in the +y direction. Each of the three magnetic detection units 30a is the same as the magnetic detection unit 30a shown in FIG. 9. The outer wall resin 10 of the power module 104 has three insertion holes 11 into which the three magnetic detection units 30a are inserted. When viewed from the insertion direction of the three magnetic detection units 30a, the three insertion holes 11 have a shape corresponding to the outer shape of the three magnetic detection units 30a. The shapes of the three insertion holes 11 are the same as the shapes shown in FIGS. 10 and 11.
[0044] FIG. 15 is a perspective view showing an example of the schematic configuration of the power module 105 in the fifth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. As shown in FIG. 15, the power module 105 includes an outer wall resin 10, a bus bar 20a protruding in the -y direction, a current path 27 connected to the bus bar 20a, a magnetic detection unit 30, a protective resin 40, and another bus bar 20c protruding in the +y direction. The current path 27 is connected to the bus bar 20a by screwing, welding, or other methods. The power module 105 in the fifth embodiment is a single-phase power module. The magnetic detection unit 30 is the same as the magnetic detection unit 30 shown in FIG. 3, and the insertion hole 11 into which the magnetic detection unit 30 is inserted is the same as the insertion hole 11 shown in FIGS. 4 and 5. Since the protective resin 40 is disposed inside the power module 105, it will be described at the location in FIG. 16.
[0045] FIG. 16 is a side cross-sectional view showing a schematic configuration of the power module 105 in the fifth embodiment. As shown in FIG. 16, the outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 23 and the protective resin 40, and a second portion 17 in which the insertion hole 11 is provided. The first portion 16 has a protruding portion 16a that supports the second portion 17 from below. In this example, the first portion 16 and the second portion 17 are formed separately. An insertion hole 11 is provided in the second portion 17, and the magnetic detection unit 30 is inserted therein. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 and the lower end portion of the substrate 31 of the magnetic detection unit 30 are in contact with each other for positioning. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed in the insertion hole 11 by the adhesive 12. Note that the power module 105 has a gap 14 between the side surface of the outer wall resin 10 forming the insertion hole 11 and the side surface of the magnetic detection unit 30 in a state where the magnetic detection unit 30 is inserted into the insertion hole 11. A part of the bus bar 20a and the current path 27 connected to the bus bar 20a are covered with the protective resin 40.
[0046] FIG. 17 is another example of a side cross-sectional view showing a schematic configuration of the power module 105 in the fifth embodiment. As shown in FIG. 17, the outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 27 and a second portion 17 in which the insertion hole 11 is provided. In another example, the first portion 16 and the second portion 17 are integrally formed. Therefore, in FIG. 17, the first portion 16 and the second portion 17 are shown with the same hatching. An insertion hole 11 is provided in the second portion 17 forming the lid, and the magnetic detection unit 30 is inserted therein. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 and the lower surface of the substrate 31 of the magnetic detection unit 30 are in contact with each other for positioning. In a state where the magnetic detection unit 30 is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed in the insertion hole 11 by the adhesive 12. An injection hole 18 for injecting the protective resin 40 is provided in the upper part of the current path 27 connected to the bus bar 20a, and the current path 27 is covered with the protective resin 40.
[0047] FIG. 18 is a perspective view showing an example of the schematic configuration of the power module 106 in the sixth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. As shown in FIG. 18, the power module 106 includes an outer wall resin 10, a bus bar 20a protruding in the -y direction, a current path 27 connected to the bus bar 20a, a magnetic detection unit 30a, and another bus bar 20c protruding in the +y direction. The power module 106 in the sixth embodiment is a single-phase power module. The magnetic detection unit 30a is the same as the magnetic detection unit 30a shown in FIG. 9. The bus bar 20a in the present embodiment is the same as the bus bar 20a in the fifth embodiment.
[0048] FIG. 19 is a side cross-sectional view showing the schematic configuration of the power module 106 in the sixth embodiment. As shown in FIG. 19, the outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 27 and the protective resin 40, and a second portion 17 provided with an insertion hole 11. In this example, the first portion 16 and the second portion 17 are formed separately. The insertion hole 11 is provided in the second portion 17, and the magnetic detection unit 30a is inserted therein. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 and the substrate 31 of the magnetic detection unit 30a are in contact with each other for positioning. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30a is fixed in the insertion hole 11 by an adhesive 12. A part of the bus bar 20a and the current path 27 connected to the bus bar 20a are covered with the protective resin 40.
[0049] FIG. 20 is another example of a side cross-sectional view showing the schematic configuration of the power module 106 in the sixth embodiment. As shown in FIG. 20, the outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 23 and the protective resin 40, and a second portion 17 provided with the insertion hole 11. In another example, the first portion 16 and the second portion 17 are integrally formed. Therefore, in FIG. 20, the first portion 16 and the second portion 17 are shown with the same hatching. The insertion hole 11 is provided in the second portion 17 forming the lid, and the magnetic detection unit 30a is inserted therein. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11, the bottom surface 11a of the outer wall resin 10 forming the insertion hole 11 and the substrate 31 of the magnetic detection unit 30a are in contact with each other for positioning. In a state where the magnetic detection unit 30a is inserted into the insertion hole 11 and positioned, the magnetic detection unit 30 is fixed in the insertion hole 11 by the adhesive 12. An injection hole 18 for injecting the protective resin 40 is provided above the current path 27 connected to the bus bar 20a, and the current path 27 is covered with the protective resin 40.
[0050] In the fifth and sixth embodiments, when the element portion 32 has two magnetoelectric conversion elements 34, 35, the magnetoelectric conversion elements 34, 35 respectively detect the strength of the magnetic field generated by the measured current flowing through the current path 27 on each magnetic sensing surface, and output detection signals corresponding to the detection intensities respectively detected by the two magnetic detection elements 34, 35. In this case, in one example, the shape of the bus bar 20a may be rectangular consisting only of the main body portion.
[0051] FIG. 21 is a perspective view showing an example of the schematic configuration of the power module 107 in the seventh embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. The power module 107 in the seventh embodiment is a power module for a three-phase motor. As shown in FIG. 21, the power module 107 includes an outer wall resin 10, three bus bars 20a protruding in the -y direction, three magnetic detection units 30, and another bus bar 20c protruding in the +y direction. The three bus bars 20a are arranged side by side in the x direction. The three bus bars 20a are the same as the bus bars 20a in FIG. 17 in the fifth and sixth embodiments, and the three magnetic detection units 30 are the same as the magnetic detection units 30 shown in FIG. 3.
[0052] The three bus bars 20a respectively correspond to the U phase, V phase, and W phase in a three-phase alternating current.
[0053] The outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 27 and the protective resin 40, and a second portion 17 provided with an insertion hole 11. The first portion 16 and the second portion 17 are integrally formed. Therefore, in FIG. 22, the first portion 16 and the second portion 17 are shown with the same hatching. The insertion hole 11 is provided in the second portion 17, and the magnetic detection unit 30 is inserted therein. The outer wall resin 10 of the power module 107 has three insertion holes 11 into which the three magnetic detection units 30 are inserted. When viewed from the insertion direction of the three magnetic detection units 30, the three insertion holes 11 have a shape corresponding to the outer shape of the three magnetic detection units 30. The shapes of the three insertion holes 11 are the same as the shapes shown in FIGS. 4 and 5.
[0054] FIG. 22 is a perspective view showing an example of the schematic configuration of the power module 108 in the eighth embodiment. In the following description, parts common to the power module 101 in the first embodiment are denoted by the same reference numerals and the description thereof is omitted. The power module 108 in the eighth embodiment is a power module for a three-phase motor. As shown in FIG. 22, the power module 108 includes an outer wall resin 10, three bus bars 20a protruding in the -y direction, three magnetic detection units 30a, and another bus bar 20c protruding in the +y direction. The three bus bars 20a are arranged side by side in the x direction. Each of the three magnetic detection units 30a is the same as the magnetic detection unit 30a shown in FIG. 9. Each of the three bus bars 20a is the same as the bus bar 20a shown in FIG. 17.
[0055] The three bus bars 20a respectively correspond to the U phase, V phase, and W phase in a three-phase alternating current.
[0056] The outer wall resin 10 has a first portion 16 surrounding at least a part of the current path 27 and the protective resin 40, and a second portion 17 provided with an insertion hole 11. The first portion 16 and the second portion 17 are integrally formed. Therefore, in FIG. 22, the first portion 16 and the second portion 17 are shown with the same hatching. An insertion hole 11 is provided in the second portion 17, and the three magnetic detection units 30a are inserted therein. When viewed from the insertion direction of the three magnetic detection units 30a, the insertion hole 11 has a shape corresponding to the outer shape of the three magnetic detection units 30a. The cross-sectional view near each bus bar 20a is the same as the cross-sectional view shown in FIG. 19.
[0057] Figures 23 to 25 are explanatory diagrams showing a part of the manufacturing process of the power module 101 in the first embodiment. Note that in Figures 23 to 25, only the configuration on the front side (-y direction side) of the power module 101 is depicted, and the protective resin 40 and the like on the back side (+y direction side) are not depicted. In the first step, the bus bar 20 shown in Figure 2 is prepared. In the second step, as shown in Figure 23, by resin molding around the bus bar 20, an outer wall resin 10 having an insertion hole 11 into which the magnetic detection unit 30 is inserted is formed. In the third step, as shown in Figure 24, the magnetic detection unit 30 is inserted into the insertion hole 11 from the +z direction. In the fourth step, as shown in Figure 25, the magnetic detection unit 30 is fixed by applying an adhesive 12 to the gap of the insertion hole 11.
[0058] Figures 26 to 28 are explanatory diagrams showing a part of the manufacturing process of the power module 102 in the second embodiment. Note that in Figures 26 to 28, only the configuration on the front side (-y direction side) of the power module 102 is depicted, and the protective resin 40 and the like on the back side (+y direction side) are not depicted. In the first step, the bus bar 20 shown in Figure 2 is prepared. As shown in Figure 26, in the second step, by resin molding around the bus bar 20, an outer wall resin 10 having an insertion hole 11 into which the magnetic detection unit 30a is inserted is formed. As shown in Figure 27, in the third step, the magnetic detection unit 30a is inserted into the insertion hole 11 from the +z direction. As shown in Figure 28, in the fourth step, the magnetic detection unit 30a is fixed by applying an adhesive 12 to the gap of the insertion hole 11.
[0059] Figs. 29 and 30 are perspective views showing an example of the schematic configuration of a modified example of the bus bar 20 used in the first to fourth embodiments. The bus bar shown in Fig. 29 has two main body portions 21 and 22 and one current path 23. As shown in Fig. 16, the two main body portions 21 and 22 are arranged side by side in the y direction. The current path 23 is disposed between the two main body portions 21 and 22 and connects the two main body portions 21 and 22. The current to be measured flows in the y direction through the current path 23. The bus bar shown in Fig. 30 has two main body portions 21 and 22, one current path 23, and a notch portion 26. The bus bar in Fig. 30 is asymmetric about the left and right.
[0060] As described above, according to the first to eleventh embodiments, the outer wall resin 10 has the insertion hole 11, and when viewed from the insertion direction of the magnetic detection portions 30 and 30a, the insertion hole 11 has a shape corresponding to the outer shape of the magnetic detection portions 30 and 30a. Thereby, the magnetic detection portions 30 and 30a can be easily inserted and fixed to the outer wall resin 10, and displacement of the magnetic detection portions 30 and 30a can also be prevented.
[0061] As described above, the present invention has been described using the embodiments, but the technical scope of the present invention is not limited to the scope described in the above embodiments. It is obvious to those skilled in the art that various changes or improvements can be made to the above embodiments. It is clear from the description of the claims that forms with such changes or improvements can also be included in the technical scope of the present invention.
[0062] It should be noted that the execution order of each process such as operations, procedures, steps, and stages in the apparatus, system, program, and method shown in the claims, the specification, and the drawings is not explicitly indicated as "earlier" or "preceding" etc., and unless the output of the previous process is used in the subsequent process, it can be realized in any order. Regarding the operation flow in the claims, the specification, and the drawings, even if it is described using "first," "next," etc. for convenience, it does not mean that it must be implemented in this order.
Description of Reference Numerals
[0063] 10 Outer wall resin, 11 Insertion hole, 11a Bottom surface, 12 Adhesive, 13 Positioning portion, 14 Gap, 15 Depression, 16 First portion, 17 Second portion, 18 Injection hole, 20 Bus bar, 20a Bus bar, 20c Other bus bar, 21 Main body portion, 22 Main body portion, 23 Current path, 24 Current path, 25 Through hole, 26 Notch portion, 27 Current path, 30 Magnetic detection portion, 30a Magnetic detection portion, 31 Substrate, 32 Element portion, 33 Connection terminal, 34 Magnetic detection element, 35 Magnetic detection element, 40 Protective resin, 101 - 108 Power modules
Claims
1. A power module having a bus bar, a magnetic detection unit, and an outer wall resin, wherein the magnetic detection unit includes a magnetic detection element, an element portion to which the magnetic detection element is fixed, and a substrate to which the element portion is fixed, the outer wall resin has an insertion hole into which the magnetic detection unit is inserted, when viewed from the insertion direction of the magnetic detection unit, the insertion hole has a shape corresponding to the outer shape of the magnetic detection unit, the outer wall resin has a positioning portion on a part of the wall surface forming the insertion hole, where the element portion of the magnetic detection unit comes into contact, a power module.
2. The magnetic detection unit includes a magnetic detection element and a substrate to which the magnetic detection element is fixed, the power module according to claim 1, wherein a plane of the substrate provided with the magnetic detection element is orthogonal to the insertion direction.
3. The magnetic detection unit includes a magnetic detection element and a substrate to which the magnetic detection element is fixed, the power module according to claim 1, wherein a plane of the substrate provided with the magnetic detection element is parallel to the insertion direction.
4. The power module according to claim 1, wherein the outer wall resin covers a part of the bus bar.
5. The power module according to claim 1, wherein in the power module, three of the bus bars are arranged side by side in a direction orthogonal to the extending direction of the bus bar.
6. The power module according to claim 1, which has only one of the bus bars.
7. The power module according to claim 1, wherein the magnetic detection unit is inserted into the insertion hole, and there is a gap between a wall surface of the outer wall resin forming the insertion hole and a side surface of the magnetic detection unit.
8. The magnetic detection unit is fixed in the insertion hole in a state where there is a gap between a wall surface of the outer wall resin forming the insertion hole and a side surface of the magnetic detection unit, the power module according to claim 1.
9. The power module according to claim 1, wherein the magnetic detection unit is inserted into the insertion hole, and a lower surface of a wall surface of the outer wall resin forming the insertion hole is in contact with a lower end portion of the magnetic detection unit.
10. The magnetic detection unit includes a magnetic detection element and a substrate to which the magnetic detection element is fixed, the power module according to claim 1, wherein the magnetic detection unit is inserted into the insertion hole, and a part of a wall surface of the outer wall resin forming the insertion hole is in contact with a lower surface of the substrate.
11. The power module according to claim 1, wherein the outer wall resin has a first portion surrounding at least a part of the bus bar and a second portion provided with the insertion hole.
12. The power module according to claim 1, wherein the bus bar is not exposed in the insertion hole.
13. The power module according to claim 1, wherein the insertion hole has a shape complementary to the outer shape of the magnetic detection portion with respect to a plane orthogonal to the insertion direction.
14. An outer wall resin for a power module having a bus bar and a magnetic detection portion, wherein the magnetic detection portion includes a magnetic detection element, an element portion to which the magnetic detection element is fixed, and a substrate to which the element portion is fixed. An insertion hole into which the magnetic detection portion is inserted. A positioning portion in a part of the wall surface forming the insertion hole, where the element portion of the magnetic detection portion comes into contact. And has The outer wall resin for a power module, wherein when viewed from the insertion direction of the magnetic detection portion, the insertion hole has a shape corresponding to the outer shape of the magnetic detection portion.
15. A method for manufacturing a power module having a bus bar and a magnetic detection portion, wherein the magnetic detection portion includes a magnetic detection element, an element portion to which the magnetic detection element is fixed, and a substrate to which the element portion is fixed. A step of resin-molding the bus bar to form an outer wall resin having an insertion hole into which the magnetic detection portion is inserted and a positioning portion for bringing the element portion of the magnetic detection portion into contact with a part of the wall surface forming the insertion hole. A step of inserting the magnetic detection portion into the insertion hole and bringing the element portion of the magnetic detection portion into contact with the positioning portion. And has A method for manufacturing a power module, wherein when viewed from the insertion direction in which the magnetic detection portion is inserted into the outer wall resin, the insertion hole has a shape corresponding to the outer shape of the magnetic detection portion.