Transformer and rectifier element mounting structure

Abstract

The present invention provides a transformer and a mounting structure for a rectifier element that is suitable for improving the conversion efficiency of the rectifier element. [Solution] A transformer and rectifier element mounting structure comprising a transformer 120 and a rectifier element section 112 composed of a plurality of rectifier elements connected to the transformer 120, wherein the electrical path connecting the transformer 120 and the rectifier element section 112 is formed as a straight line of substantially the same length for each of the plurality of rectifier elements constituting the rectifier element section 112.

Description

Technical Field

[0001] The present invention relates to a mounting structure of a transformer and a rectifying element used, for example, in a DC-DC converter of a DC power supply device.

Background Art

[0002] Conventionally, a DC power supply device is composed of a combination of an AC-DC converter and / or a DC-DC converter, and converts an input DC or AC into DC once and then further boosts or buck-boosts the DC to obtain a DC of a desired voltage.

[0003] Such a DC-DC converter generally includes a transformer for converting a voltage, a rectifying element such as a MOSFET connected to the secondary winding side of the transformer, a mounting substrate on which the rectifying element is mounted, and a bus bar for electrically connecting the rectifying element and the transformer (see, for example, Patent Documents 1 and 2).

Prior Art Documents

Patent Documents

[0004] (原文此处无内容,推测为排版问题,按要求保留原样)

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] The DC-DC converter according to the above conventional technology has the following problems. That is, in recent years, a large current has been required in a DC power supply device, and further improvement in conversion efficiency has been required.

[0006] Therefore, the main object of the present invention is to provide a mounting structure of a transformer and a rectifying element suitable for improving the conversion efficiency of the rectifying element.

Means for Solving the Problems

[0007] The first aspect of the present invention is a transformer and rectifier element mounting structure comprising a transformer and a plurality of rectifier elements connected to the transformer, wherein the electrical path connecting the transformer and the plurality of rectifier elements is formed as a straight line of substantially the same length for each of the plurality of rectifier elements.

[0008] The second aspect of the present invention is a mounting structure for a transformer and rectifier elements according to the first aspect of the present invention, wherein the plurality of rectifier elements are mounted on a mounting substrate, the electrical paths are formed in a direction that intersects with the array lines, which are lines along the arrangement of each of the plurality of rectifier elements in a plan view of the mounting substrate, and the transformer is positioned opposite the plane containing the array lines.

[0009] The third aspect of the present invention is a mounting structure for a transformer and rectifier element according to the second aspect of the present invention, wherein the array lines are formed as line segments, the electrical paths are formed in a direction substantially perpendicular to the array lines, and the surface including the array lines is formed as a plane.

[0010] The fourth aspect of the present invention is a mounting structure for a transformer and rectifier element according to the second aspect of the present invention, wherein the transformer is adjacent to the mounting substrate via the electrical path.

[0011] The fifth aspect of the present invention is a mounting structure for a transformer and rectifier elements according to the third aspect of the present invention, comprising a first heat sink that is electrically connected to the plurality of rectifier elements via the mounting substrate and extends along a direction substantially parallel to the arrangement lines to form a conductive path.

[0012] The sixth aspect of the present invention is a mounting structure for a transformer and rectifier elements according to the third aspect of the present invention, comprising a second heat sink connected to the output side of the transformer, which has a polarity different from the electrical path connecting the transformer and the plurality of rectifier elements, and which extends along a direction substantially parallel to the arrangement line to form a conductive path.

[0013] The seventh aspect of the present invention is a mounting structure for the transformer and rectifier element of the sixth aspect of the present invention, wherein the transformer is mounted on the second heat sink.

[0014] The eighth aspect of the present invention is a fifth transformer and rectifier element mounting structure of the present invention, wherein the mounting substrate comprises a first sub-mounting substrate fixed to one main surface of the first heat sink and a second sub-mounting substrate fixed to the other main surface of the first heat sink, and the plurality of rectifier elements are mounted on the first sub-mounting substrate and the second sub-mounting substrate, respectively.

[0015] The ninth aspect of the present invention is a transformer and rectifier element mounting structure of the fifth or sixth aspect of the present invention, wherein the electrical path is formed as a busbar that electrically connects the transformer and the plurality of rectifier elements, and the dimensions of the sides of the busbar along the arrangement lines are such that the dimensions of the second side on the plurality of rectifier elements side are larger or smaller than the dimensions of the first side on the transformer side.

[0016] The tenth aspect of the present invention is a mounting structure for a transformer and rectifier element of the fifth aspect of the present invention, having a cooling passage through which a refrigerant passes, provided inside the first heat sink.

[0017] The eleventh aspect of the present invention is a mounting structure for the transformer and rectifier element of the sixth aspect of the present invention, having a cooling passage through which a refrigerant passes, provided inside the second heat sink.

[0018] The twelfth aspect of the present invention has a plurality of transformer and rectifier element mounting structures of the third aspect of the present invention as substructures, wherein the substructures are array structures of transformer and rectifier element mounting structures arranged along the array lines.

[0019] The thirteenth aspect of the present invention is an array structure for a transformer and rectifier element mounting structure, wherein the second aspect of the present invention has at least one pair of mounting structures for a transformer and rectifier element as substructures, and in the pair of substructures, each of the mounting substrates is arranged opposite to the other.

[0020] The 14th invention is a DC power supply unit having an array structure of the mounting structures of the transformer and the rectifying element of the 12th or 13th invention, and outputting the output from the mounting structures of the transformer and the rectifying element as a DC output.

[0021] The 15th invention is a DC power supply device having a plurality of DC power supply units of the 14th invention, and outputting the sum of the outputs of each of the DC power supply units.

Effects of the Invention

[0022] According to the present invention, it is possible to provide a mounting structure of a transformer and a rectifying element suitable for improving the conversion efficiency of the rectifying element.

[0023] The above objects, other objects, features, and advantages of the present invention will become more apparent from the following description of the embodiments for carrying out the invention with reference to the drawings.

Brief Description of the Drawings

[0024] [Figure 1] It is a perspective view showing a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 2] It is a front view showing a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 3] It is a rear view showing a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 4] It is a left side view showing a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 5] It is an exploded perspective view showing a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 6] It is a block diagram schematically showing the configuration of a DC power supply device including a DC-DC converter having a mounting structure of a transformer and a rectifying element according to an embodiment of the present invention. [Figure 7] This is a front view showing the mounting structure of a transformer and rectifier element according to an embodiment of the present invention. [Figure 8] This is a right side view showing the mounting structure of a transformer and rectifier element according to an embodiment of the present invention. [Figure 9] Figure 7 is a cross-sectional view of the main section along the line IX-IX. [Figure 10] This is an exploded perspective view showing the mounting structure of a transformer and rectifier element according to an embodiment of the present invention. [Figure 11] This is an exploded perspective view showing the mounting structure of a transformer and rectifier element according to an embodiment of the present invention. [Figure 12] This figure schematically shows the arrangement of the transformer and rectifier element in the mounting structure of the transformer and rectifier element according to an embodiment of the present invention. [Figure 13] This figure schematically shows the arrangement of a transformer and a rectifier element in a mounting structure for a transformer and a rectifier element according to another embodiment of the present invention. [Figure 14] This figure schematically shows the arrangement of a transformer and a rectifier element in a mounting structure for a transformer and a rectifier element according to another embodiment of the present invention. [Modes for carrying out the invention]

[0025] The mounting structure of the transformer and rectifier element of the present invention will be described below in this embodiment.

[0026] (DC-DC converter) A DC-DC converter (hereinafter referred to as "DC-DC converter"), which is an example of a DC power supply unit having a transformer and rectifier element mounting structure according to an embodiment of the present invention, will be described. The DC-DC converter is configured, for example, as the final stage of a DC power supply device that converts an AC power supply, which is an external input, into a DC current of a predetermined voltage.

[0027] Figure 1 is a perspective view showing a DC-DC converter 1 according to an embodiment of the present invention. Figure 2 is a front view showing a DC-DC converter 1 according to an embodiment of the present invention. Figure 3 is a rear view showing a DC-DC converter 1 according to an embodiment of the present invention. Figure 4 is a right side view showing a DC-DC converter 1 according to an embodiment of the present invention. Figure 5 is an exploded perspective view showing the main parts of a DC-DC converter 1 according to an embodiment of the present invention. Figure 6 is a schematic block diagram showing the configuration of a DC power supply device including a DC-DC converter 1 according to an embodiment of the present invention.

[0028] As shown in each figure, the DC-DC converter 1 according to an embodiment of the present invention mainly comprises a negative electrode side block 10 connected to the positive and negative sides of the secondary output of a center-tapped transformer, to which voltages are applied to both the positive and negative sides, and which rectifies the current of the secondary output before outputting it to the outside, and a positive electrode side block 20 connected to the center tap of the transformer, to which the voltage of the center tap is applied.

[0029] The negative electrode side block 10 includes a transformer rectifier block 11 composed of four transformer rectifier blocks, and a first conductive heat sink 12 and a first terminal busbar 14, both of which have a roughly rectangular planar shape and are electrically connected to the transformer rectifier block 11. The first heat sink 12 and the first terminal busbar 14 form the conductive path on the negative electrode side of the DC-DC converter 1.

[0030] The transformer rectifier block 11 is composed of four identical sub-transformer rectifier blocks electrically connected in parallel: the first sub-transformer rectifier block 11A, the second sub-transformer rectifier block 11B, the third sub-transformer rectifier block 11C, and the fourth sub-transformer rectifier block 11D.

[0031] In the following explanation, based on the orthogonal coordinates shown in each figure, the direction in which the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, as well as the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D of the transformer rectifier block 11 are arranged will be referred to as the horizontal direction (left-right direction), the direction in which the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C, as well as the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D are arranged will be referred to as the vertical direction (up-down direction), and the direction perpendicular to both the horizontal and vertical directions will be referred to as the thickness direction (front-back direction).

[0032] Specifically, in a forward view of the DC-DC converter 1, the first sub-transformer rectifier block 11A is positioned on the upper left, the second sub-transformer rectifier block 11B is positioned on the upper right, adjacent to the right side of the first sub-transformer rectifier block 11A, the third sub-transformer rectifier block 11C is positioned on the lower left, adjacent to the lower side of the first sub-transformer rectifier block 11A, and the fourth sub-transformer rectifier block 11D is positioned on the lower right, adjacent to the right side of the third sub-transformer rectifier block 11C and adjacent to the lower side of the second sub-transformer rectifier block 11B.

[0033] Furthermore, as indicated by the letters "A" to "D" at the end of the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D described above, in the drawings referenced in this embodiment, multiple components having the same or corresponding configuration are distinguished by uppercase or lowercase letters added to the end of their numerical codes, with some exceptions.

[0034] Each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11D, which constitute the transformer rectifier block 11 shown in Figures 1 to 5, is configured as a synchronous full-wave rectifier circuit in the DC power supply device shown in Figure 6, comprising a center-tapped transformer 311 and a rectifier element 312, such as a MOSFET (metal-oxide-semiconductor field-effect transistor). The rectifier element 312 is configured as a unit consisting of a pair of rectifier elements connected in parallel: a positive-side rectifier element 312A connected to the positive terminal of the secondary side of the transformer 311 and a negative-side rectifier element 312B connected to the negative terminal of the secondary side of the transformer 311. A detailed explanation of the transformer rectifier block 11 will be given later.

[0035] In the transformer rectifier block 11 shown in Figures 1 to 5, the positive electrode rectifier element 312A and the negative electrode rectifier element 312B are each configured as a set of multiple MOSFETs, but they may also be configured as a single MOSFET.

[0036] The first heat sink 12 is a plate-shaped member of a predetermined thickness made of copper, aluminum, or other conductive metal, and is configured as a member with a substantially rectangular outer shape so as to form a conductive path that extends to the right along the arrangement direction of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B.

[0037] Inside the first heat sink 12, a refrigerant piping 13 is provided, which is a cooling passage through which the refrigerant circulates along the direction of the arrow in the figure. The refrigerant piping 13 cools the first heat sink 12 by circulating a refrigerant such as water through a circulation device in a DC power supply unit (not shown).

[0038] The first terminal busbar 14, like the first heat sink 12, is a plate-shaped member of a predetermined thickness made of copper, aluminum, or other conductive metal, and is configured as a member with a substantially rectangular outer shape so as to form a conductive path that extends further to the right along the extension direction of the first heat sink 12. The first terminal busbar 14 is electrically and thermally connected to the first heat sink 12 via a connecting member 15, and DC power is extracted from its end 14E.

[0039] The positive electrode side block 20 has connection terminals 21A, 21B, 21C, and 21D for electrically connecting to the center tap of the transformer 120 of the transformer rectifier block 11, and a conductive second heat sink 22 and a second terminal busbar 24 which are electrically connected to the transformer rectifier block 11. The second heat sink 22 and the second terminal busbar 24 form the conductive path on the positive electrode side of the DC-DC converter 1.

[0040] Connection terminal 21A is connected to the first sub-transformer rectifier block 11A. Connection terminal 21B is connected to the second sub-transformer rectifier block 11B, and connection terminal 21C is connected to the third sub-transformer rectifier block 11C. Connection terminal 21D is connected to the fourth sub-transformer rectifier block 11D.

[0041] The connection terminals 21A to 21D protrude from the surface of the second heat sink 22, creating an air gap C between the transformer rectifier block 11 and the second heat sink 22 in the DC-DC converter 1. The connection terminals 21A to 21D are preferably made of copper, but any conductive metallic material can be used.

[0042] Inside the second heat sink 22, a pair of cooling channels, or refrigerant pipes 23, are arranged along the direction of the arrows in the figure, through which the refrigerant circulates. The refrigerant pipes 23 cool the second heat sink 22 by circulating a refrigerant such as water through a circulation device in a DC power supply unit (not shown).

[0043] The second heat sink 22 is configured as a combination of a first sub-heat sink 22a and a second sub-heat sink 22b, which are a pair of planar rectangular heat sinks arranged adjacent to each other vertically. Each of the first sub-heat sink 22a and the second sub-heat sink 22b is a plate-shaped member of a predetermined thickness made of copper, aluminum, or other conductive metal, and is configured as a member with a substantially rectangular outer shape so as to be parallel to the first heat sink 12 and to form a conductive path that extends to the right along the arrangement direction of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B.

[0044] Inside the first sub-heat sink 22a, one of the refrigerant pipes 23, the first sub-refrigerant pipe 23a, is installed, and inside the second sub-heat sink 22b, the other of the refrigerant pipes 23, the second sub-refrigerant pipe 23b, is installed.

[0045] The second terminal busbar 24, like the second heat sink 22, is a plate-shaped member of a predetermined thickness made of copper, aluminum, or other conductive metal, and is configured as a member with a substantially rectangular outer shape so as to form a conductive path that extends further to the right along the extension direction of the second heat sink 22. The second terminal busbar 24 is electrically and thermally connected to the second heat sink 22 via a connecting member 25, and DC power is extracted from the end 24E.

[0046] (DC power supply) The main components of the DC power supply device including the DC-DC converter 1 according to an embodiment of the present invention will be described with reference to the block diagram in Figure 6.

[0047] The DC power supply unit comprises an AC-DC converter 100 that receives an AC current input Ia and converts it into a square wave output Oa, a primary DC-DC converter 200 that transforms the output Oa of the AC-DC converter 100 into an output Od1, and a secondary DC-DC converter 300 that transforms and rectifies the output Od1 of the primary DC-DC converter 200 into an output Od2, which is the final stage DC current of the DC power supply unit. In the secondary DC-DC converter 300, the output Od2 has the positive terminal OdP and the negative terminal OdN as output terminals. However, the DC power supply unit including the DC-DC converter 1 according to the embodiment of the present invention is not limited to the above configuration, and may consist of a combination of an AC-DC converter and / or a DC-DC converter, and can obtain a DC of a desired voltage by further boosting or stepping up the DC after converting the input DC or AC to DC.

[0048] The AC-DC converter 100 is configured as a PFC circuit. The primary DC-DC converter 200 and the secondary DC-DC converter 300 are configured as switching regulators. The secondary DC-DC converter 300 is an example of the DC power supply unit of the present invention and corresponds to the DC-DC converter 1 shown in Figures 1 to 5.

[0049] The secondary DC-DC converter 300 consists of four identical sub-transformer rectifier blocks electrically connected in parallel: a first sub-transformer rectifier block 310A, a second sub-transformer rectifier block 310B, a third sub-transformer rectifier block 310C, and a fourth sub-transformer rectifier block 310D. The first sub-transformer rectifier block 310A corresponds to the first sub-transformer rectifier block 11A in the DC-DC converter 1, the second sub-transformer rectifier block 310B corresponds to the second sub-transformer rectifier block 11B in the DC-DC converter 1, the third sub-transformer rectifier block 310C corresponds to the third sub-transformer rectifier block 11C in the DC-DC converter 1, and the fourth sub-transformer rectifier block 310D corresponds to the fourth sub-transformer rectifier block 11D in the DC-DC converter 1.

[0050] The configuration of the sub-transformer rectifier block will be explained below, using the first sub-transformer rectifier block 310A as an example. The first sub-transformer rectifier block 310A is configured as a synchronous full-wave rectifier circuit comprising a center-tapped transformer 311, a positive-side rectifier element 312A and a negative-side rectifier element 312B connected to the transformer 311, and a mounting board 313 on which the positive-side rectifier element 312A and the negative-side rectifier element 312B are mounted.

[0051] The transformer 311 has terminals including a positive primary terminal 311a1 that receives the positive terminal of the output Od1 of the primary DC-DC converter 200, a negative primary terminal 311b1 that is connected to the positive primary terminal of the transformer of the adjacent second sub-transformer rectifier block 310B, secondary terminals 311a2 and 311b2 of the same polarity to which the transformed voltage is applied, and a center tap 311c that provides a reference potential for the secondary terminals 311a2 and 311b2.

[0052] Furthermore, the primary terminals of the transformers in the first sub-transformer rectifier block 310A to the fourth sub-transformer rectifier block 310D are electrically connected in series. Therefore, the negative terminal of the output Od1 of the primary DC-DC converter 200 is connected to the primary terminal of the negative terminal of the transformer in the fourth sub-transformer rectifier block 310D, and the primary terminals of the transformers in the other sub-transformer rectifier blocks are connected with opposite polarities.

[0053] As described above, the rectifier element 312 is configured as a unit consisting of a pair of rectifier elements connected in parallel: a positive-side rectifier element 312A connected to the positive terminal on the secondary side of the transformer 311, and a negative-side rectifier element 312B connected to the negative terminal on the secondary side of the transformer 311. Specifically, the drain electrode of the positive-side rectifier element 312A is connected to the secondary side terminal 311a2, and the drain electrode of the negative-side rectifier element 312B is connected to the secondary side terminal 311b2. Furthermore, the source electrodes of the positive-side rectifier element 312A and the negative-side rectifier element 312B are connected to the negative terminal connection terminal OdN of the secondary DC-DC converter 300.

[0054] As mentioned above, the positive electrode rectifier element 312A and the negative electrode rectifier element 312B are specifically configured as a set of one or more MOSFETs.

[0055] In the secondary DC-DC converter 300, several electrical paths connecting each part are configured as printed circuit boards, vias, or other wiring built into the mounting board 313, or as electrical paths using components independent of such wiring.

[0056] Specifically, the electrical path between the positive secondary terminal 311a2 of the transformer 311 and the mounting board 313 is configured as an electrical path 314a made of components independent of the wiring incorporated into the mounting board 313. The electrical path between the negative secondary terminal 311b2 of the transformer 311 and the mounting board 313 is configured as an electrical path 314b made of components independent of the wiring incorporated into the mounting board 313.

[0057] The electrical path from electrical path 314a to the drain electrode of the positive side rectifier element 312A of the rectifier element 312 is configured as electrical path 318a, which is built into the mounting substrate 313. The electrical path from electrical path 314b to the drain electrode of the negative side rectifier element 312B of the rectifier element 312 is configured as electrical path 318b, which is built into the mounting substrate 313.

[0058] The electrical path from the source electrode of the positive-side rectifier element 312A of the rectifier element 312 to the connection point (hereinafter referred to as "connection point") CG of the respective source electrodes of the positive-side rectifier element 312A and the negative-side rectifier element 312B is configured as an electrical path 315a made of components independent of the wiring fabricated on the mounting board 313. The electrical path from the source electrode of the negative-side rectifier element 312B of the rectifier element 312 to the connection point CG is configured as an electrical path 315b made of components independent of the wiring fabricated on the mounting board 313.

[0059] The electrical path between the connection point CG and the negative terminal OdN of the output Od2 of the secondary DC-DC converter 300 is configured as an electrical path 316 made of components independent of the wiring incorporated into the mounting board 313. The electrical path between the center tap 311c of the transformer 311 and the positive terminal OdP of the output Od2 of the secondary DC-DC converter 300 is configured as an electrical path 317 made of components independent of the wiring incorporated into the mounting board 313.

[0060] In the first sub-transformer rectifier block 310A having the above configuration, control voltages are alternately applied from the drive circuit 319 of the secondary DC-DC converter 300 to the gate electrodes of the positive-side rectifier element 312A and the negative-side rectifier element 312B, causing the positive-side rectifier element 312A and the negative-side rectifier element 312B to switch, thereby rectifying the output on the secondary side of the transformer 311. The pulsating current after rectification may be smoothed by a smoothing circuit not shown in Figure 6. This provides the final DC current for the DC power supply.

[0061] In parallel with the operation of the first sub-transformer rectifier block 310A, the second sub-transformer rectifier block 310B, the third sub-transformer rectifier block 310C, and the fourth sub-transformer rectifier block 310D also perform similar operations. The DC output of the DC power supply is then obtained as the sum of the DC currents of the final stage of each sub-transformer rectifier block.

[0062] (Transformer and rectifier block) A transformer-rectifier block 11 incorporating a transformer and rectifier element mounting structure according to an embodiment of the present invention will now be described. The transformer-rectifier block 11 is a block in the DC-DC converter 1 that transforms and rectifies the primary output converted from AC to DC, and outputs it as DC current to the negative side block 10 and positive side block 20 of the DC-DC converter 1. Furthermore, as described above, the first sub-transformer-rectifier block 11A to the fourth sub-transformer-rectifier block 11D of the transformer-rectifier block 11 correspond to the first sub-transformer-rectifier block 310A to the fourth sub-transformer-rectifier block 310D shown in Figure 6, respectively.

[0063] Figure 7 is a front view of the transformer rectifier block 11. Figure 8 is a right side view of the transformer rectifier block 11. Figure 9 is a cross-sectional view of the main part along the line IX-IX in Figure 7. Figure 10 is a perspective view of the transformer rectifier block 11. However, in Figure 10, a portion is shown as an exploded view.

[0064] The transformer rectifier block 11 mainly comprises a circuit section 110 including at least a rectifier element section 112, a transformer 120 electrically connected to the rectifier element section 112, and a conductive section 130 that forms an electrical path between the transformer 120, the circuit section 110, and the negative electrode block 10.

[0065] The circuit section 110 includes a mounting board 111 consisting of a first sub-mounting board 111A exposed on the surface side in the DC-DC converter 1 and a second sub-mounting board 111B facing the second heat sink 22 of the positive electrode side block 20, and a rectifier element section 112 and a drive circuit 113 mounted on the first sub-mounting board 111A and the second sub-mounting board 111B, respectively. The mounting board 111 corresponds to the mounting board 313 in each of the first sub-transformer rectifier blocks 310A to the fourth sub-transformer rectifier blocks 310D shown in Figure 6.

[0066] The configuration of the circuit section 110 will be explained below using the first sub-mounting board 111A as an example, but the second sub-mounting board 111B has basically the same configuration.

[0067] The first sub-mounting substrate 111A is formed in the shape of a rectangular plate with a planar shape, having a front surface 111F and a back surface 111R as a pair of main surfaces, and the rectifier element section 112 and the drive circuit 113 are mounted on the front surface 111F.

[0068] The rectifier element section 112 is composed of a pair of rectifier element groups, rectifier element group 112A and rectifier element group 112B, which are arranged in a horizontal line at a predetermined interval on the surface 111F of the first sub-mounting substrate 111A. Each of rectifier element group 112A and rectifier element group 112B is further composed of multiple rectifier elements that are arranged in a horizontal line at equal intervals to form an array line AL, which is a line segment, in a plan view along the first sub-mounting substrate 111A, and are electrically connected in parallel. In other words, all rectifier elements constituting the rectifier element section 112 are arranged in a straight line along the horizontal direction in a plan view along the first sub-mounting substrate 111A.

[0069] Furthermore, the array line AL formed by each of the multiple rectifier elements of the rectifier element section 112 is the reference for the orthogonal coordinates in each figure and defines the direction of each part of the DC-DC converter 1, including the mounting structure of the transformer and rectifier elements of the present invention and the transformer rectifier block 11.

[0070] For example, regarding the arrangement of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11D that constitute the transformer rectifier block 11, the arrangement of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and the arrangement direction of the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D are oriented approximately parallel to the arrangement line AL. The arrangement of the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C, and the arrangement direction of the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D are oriented approximately perpendicular to the arrangement line AL.

[0071] Similarly, the first heatsink 12 and first terminal busbar 14 of the negative electrode block 10, and the second heatsink 22 and second terminal busbar 24 of the positive electrode block 20 are formed to extend in a direction substantially parallel to the array line AL.

[0072] The rectifier element group 112A corresponds to the positive electrode rectifier element 312A in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown in Figure 6, and the rectifier element group 112B corresponds to the negative electrode rectifier element 312B in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown in Figure 6.

[0073] Each of the multiple rectifier elements constituting the rectifier element section 112 is an element that rectifies the output from the transformer 120, and as mentioned above, a MOSFET is used as an example. However, each of the rectifier elements constituting the rectifier element section 112 is not limited by its specific configuration as long as it is an active element capable of performing a rectifying action, and for example, an IGBT (insulated gate bipolar transistor) can also be used. Furthermore, it is preferable that each of the rectifier elements constituting the rectifier element section 112 is a power transistor that can handle a large current of at least 50A.

[0074] Referring particularly to Figures 7 and 9, each of the rectifier elements constituting the rectifier element section 112, taking the rectifier element 121B1 at the right end of the rectifier element group 112B as an example, has a drain electrode 112a provided so as to be exposed on the surface facing the surface 111F of the mounting substrate 111, a source electrode 112b extending downward along the surface 111F of the mounting substrate 111, and a gate electrode 112c extending upward along the surface 111F of the mounting substrate 111.

[0075] The drive circuit 113 is a circuit connected to the gate electrode of each rectifier element constituting the rectifier element section 112, and is a means for performing the switching operation of the rectifier element section 112. In the figure, the drive circuit 113 is schematically shown as a single block, consisting of a first sub-drive circuit 113a that drives the rectifier element group 112A and a second sub-drive circuit 113b that drives the rectifier element group 112B.

[0076] Transformer 120 is a center-tapped planar transformer, and has a configuration in which multiple primary coils 121, which are thin flat wire coils, and multiple secondary coils 122, which are flexible substrate coils, are alternately stacked and wound around and housed in a PQ core 123. Transformer 120 corresponds to transformer 311 in the synchronous full-wave rectifier circuit of the sub-transformer rectifier block shown in Figure 6.

[0077] Multiple primary coils 121 are electrically connected to the primary output circuit, which is the upstream stage of the DC-DC converter 1 (not shown in Figures 1-5), via primary start ends 121a and primary end ends 121b. Specifically, the primary start ends 121a and primary end ends 121b are led to the upper side of the transformer 120 and connected to the primary output circuit of the DC-DC converter 1 by wiring (not shown).

[0078] In Figure 6, the primary output circuit of the DC-DC converter 1 described above is shown as the primary DC-DC conversion unit 200, and the primary start end 121a and primary end end 121b of the primary coil 121 shown in Figure 7 are shown as the positive terminal primary end 311a1 and the negative terminal primary end 311b1, respectively.

[0079] The multiple secondary coils 122 are laminates of flexible substrate coils having a secondary start end 122a (where the winding begins) and a secondary intermediate end 122c (where the winding ends), and flexible substrate coils having a secondary start end 122b (where the winding begins) and a secondary intermediate end 122c (where the winding ends). The secondary start ends 122a and 122b give potentials of opposite polarity to each other. That is, if the secondary start end 122a is the positive electrode, then the secondary start end 122b is the negative electrode, and if the secondary start end 122a is the negative electrode, then the secondary start end 122b is the positive electrode. The secondary intermediate end 122c provides the neutral point for the secondary start ends 122a and 122b. Specifically, the secondary start ends 122a and 122b give the negative potential to the DC-DC converter 1. The secondary intermediate end 122c gives the positive potential to the DC-DC converter 1.

[0080] The secondary side start ends 122a and 122b are electrically connected to the mounting board 111 of the circuit section 110. The secondary side intermediate end 122c is electrically connected to the positive electrode block 20.

[0081] Specifically, in Figure 7, the secondary side starting end 122a, the secondary side starting end 122b, and the secondary side intermediate end 122c are pulled out to the lower side of the transformer 120 and arranged in a single line horizontally, as shown in Figure 7.

[0082] The secondary start ends 122a of the multiple secondary coils 122 are coupled to a cylindrical coupling terminal 124a. The coupling terminal 124a is electrically connected to the rectifier element section 112 by being fixed onto the first sub-mounting substrate 111A via a busbar 131a of the first sub-conducting section 130a, which will be described later.

[0083] The secondary start ends 122b of multiple secondary coils 122 are coupled to cylindrical coupling terminals 124b. The coupling terminals 124b are electrically connected to the rectifier element section 112 by being fixed onto the first sub-mounting substrate 111A via a busbar 131b of a second sub-conducting section 130b, which will be described later.

[0084] The secondary intermediate ends 122c of multiple secondary coils 122 are coupled to cylindrical coupling terminals 124c. The coupling terminals 124c of the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D are fixed to and electrically connected to the positive electrode block 20 via connection terminals 21A to 21D.

[0085] Furthermore, the secondary starting end 122a of the secondary coil 122 shown in Figure 7 corresponds to the positive terminal secondary end 311a2 in Figure 6, the secondary starting end 122b of the secondary coil 122 shown in Figure 7 corresponds to the positive terminal secondary end 311b2 in Figure 6, and the secondary intermediate end 122c of the secondary coil 122 shown in Figure 7 corresponds to the center tap 311c in Figure 6.

[0086] The conductive portion 130 consists of a first sub-conductive portion 130a that forms a negative potential electrical path between the transformer 120 and the negative electrode side block 10 via a coupling terminal 124a, and a second sub-conductive portion 130b that forms a negative potential electrical path between the transformer 120 and the negative electrode side block 10 via a coupling terminal 124b.

[0087] The first sub-conductive section 130a consists of busbars 131a and 132a (see the area enclosed by the dashed line in Figure 7) and connecting pins 133a, which electrically connect the coupling terminal 124a and the rectifier element section 112 and also connect the transformer 120 and the mounting substrate 111.

[0088] The second sub-conductive section 130b consists of busbars 131b and 132b (see the area enclosed by the dashed line in Figure 7) and connecting pins 133b, which electrically connect the coupling terminal 124b and the rectifier element section 112 and also connect the transformer 120 and the mounting substrate 111.

[0089] The first sub-conductive portion 130a and the second sub-conductive portion 130b have a shape that is symmetrical with respect to a straight line passing through the coupling terminal 124b in the vertical direction when viewed in plan along the mounting substrate 111. Specifically, the busbars 131a and 131b have a symmetrical shape, and the busbars 132a and 132b have the same shape. Therefore, in the following description, the second sub-conductive portion 130b will be used as an example with reference to Figures 7 to 10, but the first sub-conductive portion 130a has a similar configuration except for the shape described above.

[0090] The busbar 131b is constructed as a plate-like member of a predetermined thickness, made of copper, aluminum, or other conductive metal, in single or multiple layers. When the width dimension of the busbar 131b is defined as the dimension along the arrangement line AL of the rectifier element group 112B, the width dimension on the rectifier element group 112B side (second side) is larger than the width dimension on the coupling terminal 124b side (first side) of the transformer 120, and the width gradually increases in between, giving the busbar 131b an outline that is roughly trapezoidal in plan view along the mounting substrate 111.

[0091] As a result, in a front view along the mounting substrate 111, the busbar 131b extends in a direction substantially perpendicular to the arrangement line AL of the rectifier element group 112B, and the electrical path formed by the busbar 131b, connecting the coupling terminal 124b to each of the multiple rectifier elements constituting the rectifier element group 112B, is formed as a straight line of substantially the same length for each of the multiple rectifier elements.

[0092] In this configuration, the transformer 120 is positioned opposite the arrangement line AL of the rectifier element group 112B, with the busbar 131b in between.

[0093] In the right side view shown in Figures 8 and 9, the busbar 131b has a shape that is bent by bellows folding, including one mountain fold and one valley fold, so that the contact surface C1 with the end face of the coupling terminal 124b and the contact surface C2 with the mounting substrate 111 are aligned parallel to each other and offset in the front-to-back direction.

[0094] The busbar 132b is constructed as a plate-shaped member made of copper, aluminum, or other conductive metal, having a roughly rectangular shape in plan view. In particular, as shown in Figure 9, the busbar 132b extends in the vertical direction from a position overlapping with the busbar 131b to a position facing the multiple rectifier elements that constitute the rectifier element section 112. It is preferable that the busbar 132b is formed from a single layer of metal plate that is thicker than the one used for the busbar 131b.

[0095] The busbar 132b is fixed to the back surface 111R of the mounting substrate 111, which is the side on which the rectifier element section 112 and the drive circuit 113 are not mounted. At this time, the mounting substrate 111 is sandwiched between the contact surface C2 of the busbar 132b and the busbar 131b.

[0096] Next, as shown in Figures 9 and 10, the busbar 132b incorporated into the transformer rectifier block 11 is mechanically fixed to and insulated from the first heat sink 12 of the negative electrode block 10 (see Figure 11) via an insulating member 117. Specifically, the surface of the first heat sink 12 to which the busbar 132b is fixed is recessed by the thickness of the busbar 132b, creating a step compared to the other parts of the first heat sink 12 and forming a recess 12x (see Figure 11) that is exposed as the surface of the insulating member 117. As a result, the transformer rectifier block 11 is mounted on the negative electrode block 10 (see Figure 11) in a state where both the busbar 132b and the mounting substrate 111 are in contact only with the surface of the insulating member 117 and are insulated from the first heat sink 12.

[0097] Next, the electrical and mechanical connections between the transformer 120, the conductive part 130, the rectifier element part 112, and the first heat sink 12 are configured as follows.

[0098] The connection between the transformer 120 and the conductive part 130 is configured as follows, taking the first sub-mounting board 111A as an example, as shown in Figures 7 and 10: The coupling terminal 124a of the transformer 120 and the busbar 131a are electrically and mechanically coupled by fastening with a connecting pin 137a, and the coupling terminal 124b and the busbar 131b are electrically and mechanically coupled by fastening with a connecting pin 137b. The busbar 131a and the busbar 132a are electrically and mechanically coupled by fastening with a connecting pin 133a that penetrates the first sub-mounting board 111A, and the busbar 131b and the busbar 132b are electrically and mechanically coupled by fastening with a connecting pin 133b that penetrates the first sub-mounting board 111A.

[0099] In Figure 7, the second sub-mounting board 111B, which is on the back side and not shown as a blind spot, is arranged such that the left and right sides of the first sub-conductive part 130a and the second sub-conductive part 130b are swapped with those of the first sub-mounting board 111A. Therefore, in the second sub-mounting board 111B, the coupling terminal 124a of the transformer 120 and the busbar 131a are electrically and mechanically coupled by fastening with connecting pin 137a, and the coupling terminal 124b and the busbar 131b are electrically and mechanically coupled by fastening with connecting pin 137b. The busbars 131a and 132a are electrically and mechanically coupled by fastening with connecting pin 133a that penetrates the first sub-mounting board 111A, and the busbars 131b and 132b are electrically and mechanically coupled by fastening with connecting pin 133b that penetrates the first sub-mounting board 111A.

[0100] Next, the connection between the conductive part 130 and the rectifier element part 112 is configured as follows, taking the rectifier element 121B1 at the right end of the rectifier element group 112B as an example, as shown in Figure 9. The drain electrode 112a and the busbar 131b, which are provided to be exposed on the surface facing the surface 111F of the mounting substrate 111, are joined via a conductive via 134b that penetrates from the surface 111F to the back surface 111R of the mounting substrate 111, thereby establishing an electrical connection.

[0101] Next, the electrical connection between the rectifier element section 112 and the first heat sink 12 is configured as follows, taking the rectifier element 121B1 at the right end of the rectifier element group 112B as an example, as shown in Figure 9. The source electrode 112b, which is provided to extend downward along the surface 111F of the mounting substrate 111, and the first heat sink 12 are joined via a conductive connection pin 136b, which is provided to penetrate from the surface 111F to the back surface 111R of the mounting substrate 111, and a conductive connection member 135b that is electrically connected to the connection pin 136b, thereby establishing an electrical connection.

[0102] Furthermore, a smoothing circuit, not shown in Figures 7-10, may be provided between the rectifier element 112 and the first heat sink 12.

[0103] The electrical connection between the rectifier element section 112 and the drive circuit 113 is configured as follows. In particular, as shown in Figure 7, the first sub-drive circuit 113a is electrically connected by the connection of the gate wiring 114a, which is configured as printed wiring on the mounting substrate 111, and the gate electrodes of each of the multiple rectifier elements constituting the rectifier element group 112A, on the surface 111F of the mounting substrate 111.

[0104] Similarly, the second sub-drive circuit 113b is electrically connected by the connection of the gate wiring 114b, which is configured as printed circuitry on the mounting substrate 111, and the gate electrodes of each of the multiple rectifier elements constituting the rectifier element group 112B, on the surface 111F of the mounting substrate 111.

[0105] In the transformer rectifier block 11 having the above configuration, in a plan view along the mounting substrate 111, the transformer 120 and the mounting substrate 111 are arranged opposite each other with the busbar 131b in between. In other words, the transformer 120 is adjacent to the mounting substrate 111 via the busbar 131b, which is an electrical path.

[0106] The conductive part 130 shown in Figures 7 to 10 corresponds to the following parts in the secondary DC-DC converter 300 of the DC power supply shown in Figure 6. Specifically, the busbars 131a and 132a and the connecting pin 133a correspond to the electrical path 314a between the positive secondary end 311a2 of the transformer 311 and the mounting substrate 313, and the busbars 131b and 132b and the connecting pin 133b correspond to the electrical path 314b between the negative secondary end 311b2 of the transformer 311 and the mounting substrate 313.

[0107] The connecting member 135a and connecting pin 136a shown in Figures 7 to 10 correspond to the electrical path 315a from the source electrode of the positive side rectifier element 312A of the rectifier element 312 shown in Figure 6 to the connection point CG, the connecting member 135b and connecting pin 136b, and the busbar 132b, correspond to the electrical path 315b from the source electrode of the negative side rectifier element 312B of the rectifier element 312 to the connection point CG.

[0108] The busbars 132a and (not shown) vias 134a shown in Figures 7 to 10 correspond to the electrical path 318a from the electrical path 314a shown in Figure 6 to the drain electrode of the positive side rectifier element 312A of the rectifier element 312, and the busbars 132b and vias 134b correspond to the electrical path 318b from the electrical path 314b to the drain electrode of the negative side rectifier element 312B of the rectifier element 312.

[0109] The first heatsink 12 and the first terminal busbar 14 shown in Figures 1 to 3 and 5 correspond to the electrical path 316 between the connection point CG shown in Figure 6 and the negative terminal OdN of the output Od2 of the secondary DC-DC converter 300. The second heatsink 22 and the second terminal busbar 24 shown in Figures 1 to 3 and 5 correspond to the electrical path 317 between the center tap 311c of the transformer 311 shown in Figure 6 and the positive terminal OdP of the output Od2 of the secondary DC-DC converter 300.

[0110] Furthermore, the gate wiring 114a connecting the first sub-drive circuit 113a and the rectifier element group 112A of the drive circuit 113 shown in Figures 7 and 9 corresponds to the gate wiring 320a between the drive circuit 319 and the positive-side rectifier element 312A. The gate wiring 114b connecting the second sub-drive circuit 113b and the rectifier element group 112B of the drive circuit 113 shown in Figures 7 and 9 corresponds to the gate wiring 320b between the drive circuit 319 and the negative-side rectifier element 312B shown in Figure 6.

[0111] The negative electrode block 10 and positive electrode block 20, on which the transformer rectifier block 11 is mounted, are integrally fixed by a pair of brackets, bracket 30a and bracket 30b. Specifically, bracket 30a is positioned across the first heat sink 12 of the negative electrode block 10, which is exposed adjacent to the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C of the transformer rectifier block 11, and the second heat sink 22 of the positive electrode block 20, and is fastened to the first heat sink 12 and the second heat sink 22, respectively. Similarly, the bracket 30b is positioned across the first heat sink 12 of the negative electrode side block 10, which is exposed adjacent to the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D of the transformer rectifier block 11, and the second heat sink 22 of the positive electrode side block 20, and is fastened to the first heat sink 12 and the second heat sink 22, respectively.

[0112] Furthermore, the transformer 120 of the first sub-transformer rectifier block 11A is fixed to the positive terminal block 20 by bracket 31a. Similarly, the transformer 120 of the second sub-transformer rectifier block 11B is fixed to the positive terminal block 20 by bracket 31b, the transformer 120 of the third sub-transformer rectifier block 11C is fixed to the positive terminal block 20 by bracket 31c, and the transformer 120 of the fourth sub-transformer rectifier block 11D is fixed to the positive terminal block 20 by bracket 31b.

[0113] As a result, the transformers 120 included in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier block 11D, which constitute the transformer rectifier block 11, are all mounted so as to be thermally connected to the second heat sink 22.

[0114] In the DC-DC converter 1, the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, located on the upper side, are arranged left and right along the arrangement line AL of the rectifier element section 112, with the transformer 120 positioned upwards. The third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D, located on the lower side, are arranged left and right along the arrangement line AL of the rectifier element section 112, with the transformer 120 positioned downwards. In other words, the pair of blocks, the first sub-transformer rectifier block 11A located on the upper side and the third sub-transformer rectifier block 11C located downwards, and the pair of blocks, the second sub-transformer rectifier block 11B located on the upper side and the fourth sub-transformer rectifier block 11D located downwards, are arranged with their mounting boards 111 facing each other.

[0115] In this configuration, each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier block 11D is an example of a substructure of the present invention, and the arrangement of the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, as well as the arrangement of the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D, is an example of an arrangement structure for the mounting structure of the transformer and rectifier element of the present invention. Furthermore, the arrangement of the first sub-transformer rectifier block 11A and the third sub-transformer rectifier block 11C, as well as the arrangement of the second sub-transformer rectifier block 11B and the fourth sub-transformer rectifier block 11D, is an example of an arrangement structure for the mounting structure of the transformer and rectifier element of the present invention.

[0116] In the DC-DC converter 1 according to an embodiment of the present invention having the above configuration, the mounting structure of the transformer and rectifier elements in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier block 11D constituting the transformer rectifier block 11 is configured as follows. That is, the transformer 120 is positioned opposite the array line AL of the rectifier element section 112 with busbars 131a and 131b in between, and the transformer 120 and the rectifier element section 112 are connected to busbars 131a and 131b which extend in a direction substantially perpendicular to the array line AL of the rectifier element section 112, so that the electrical path connecting the coupling terminal 124b to each of the plurality of rectifier elements constituting the rectifier element section 112 is formed as a straight line of substantially the same length for each of the plurality of rectifier elements.

[0117] This means that the electrical paths between the transformer 120 and each of the multiple rectifier elements of the rectifier element section 112, that is, the electrical path 314a between the positive secondary end 311a2 of the transformer 311 and the mounting substrate 313, and the electrical path 314b between the negative secondary end 311b2 of the transformer 311 and the mounting substrate 313, respectively, in the secondary DC-DC conversion section 300 of the DC power supply device shown in Figure 6, are minimized with respect to the positive rectifier element 312A and the negative rectifier element 312B of the rectifier element 312.

[0118] This reduces losses in the transformer 120, the rectifier element section 112, and the busbars 131b and 131b that constitute the electrical path, thereby improving the conversion efficiency of the rectifier element section 112. Consequently, it becomes possible to suppress heat generation in the transformer 120, the rectifier element section 112, and the busbars 131b and 131b that constitute the electrical path, thereby obtaining a highly efficient DC-DC converter suitable for DC power supply devices handling large currents, and a DC power supply device equipped with it.

[0119] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in each of the first sub-transformer rectifier blocks 11A to the fourth sub-transformer rectifier blocks 11D that constitute the transformer rectifier block 11 is configured as follows. That is, the transformer 120 and the mounting substrate 111 are arranged opposite each other with busbars 131a and 131b in between, so that the transformer 120 is adjacent to the mounting substrate 111 via the electrical paths of busbars 131a and 131b.

[0120] As a result, the electrical paths between the transformer 120 and each of the multiple rectifier elements of the rectifier element section 112 are brought into close proximity, reducing losses in the transformer 120, the rectifier element section 112, and the busbars 131a and 131b that constitute the electrical paths, thereby improving the conversion efficiency of the rectifier element section 112. Consequently, heat generation in the transformer 120, the rectifier element section 112, and the busbars 131b that constitute the electrical paths is suppressed, making it possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices handling large currents, and a DC power supply device equipped with it.

[0121] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, it is equipped with a first heat sink 12 that is electrically connected to the rectifier element section 112 via the mounting substrate 111 and extends along a direction substantially parallel to the array line AL to form a conductive path.

[0122] This allows the conductive path of the DC-DC converter 1, in which the transformer and rectifier element mounting structure is incorporated, specifically the electrical path 316 between the connection point CG and the negative terminal OdN of the output Od2 of the secondary DC-DC converter 300 of the DC power supply unit shown in Figure 6, to be configured with a short distance while maintaining heat dissipation. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supplies handling large currents, and a DC power supply unit equipped with such a converter.

[0123] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. Specifically, the transformer 120 is electrically connected to the secondary intermediate terminal 122c, which is the output side and has a different polarity from the electrical path connecting the transformer 120 and the rectifier element section 112, and is equipped with a second heat sink 22 that extends in a direction substantially parallel to the array line AL and forms a conductive path.

[0124] This allows the conductive path of the DC-DC converter 1, in which the transformer and rectifier element mounting structure is incorporated, specifically the electrical path 315 between the source electrode of the negative rectifier element 312B of the rectifier element 312 in the secondary DC-DC conversion section 300 of the DC power supply unit shown in Figure 6, and the connection point CG, to be configured with a short distance while maintaining heat dissipation. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supplies that handle large currents, and a DC power supply unit equipped with such a converter.

[0125] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, the transformers 120 included in each of the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D that constitute the transformer rectifier block 11 are all mounted so as to be thermally connected to the second heat sink 22.

[0126] This allows the heat generated by the transformer 120 to be conducted to the second heat sink 22, thereby efficiently cooling the transformer 120. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supplies handling large currents, and a DC power supply equipped therewith.

[0127] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer-rectifier block 11 is configured as follows. That is, both the first sub-mounting board 111A and the second sub-mounting board 111B in the transformer-rectifier block 11 are fixed in surface contact with the main surface of the first heat sink 12, and a rectifier element section 112 is mounted on each of the first sub-mounting board 111A and the second sub-mounting board 111B.

[0128] As a result, in the transformer rectifier block 11, a large number of rectifier elements constituting the rectifier element section 112 can be mounted in a space-saving manner, and the mounting density can be efficiently increased.

[0129] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, when the width dimension of the busbars 131a and 131b in the transformer rectifier block 11 is defined as the dimension along the arrangement line AL of the rectifier element section 112, the width dimension on the rectifier element section 112 side (second side) is larger than the width dimension on the coupling terminal 124b side (first side) of the transformer 120.

[0130] This improves the heat dissipation of busbars 131a and 131b, suppressing heat generation in the transformer 120, the rectifier element section 112, and the busbars 131a and 131b, which are the actual components of the electrical path, thereby improving the conversion efficiency of the rectifier element section 112. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices that handle large currents, and a DC power supply device equipped with it.

[0131] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, a refrigerant pipe 13, which is a cooling passage through which the refrigerant circulates, is arranged inside the first heat sink 12 of the negative electrode block 10.

[0132] This makes it possible to improve the cooling efficiency of the DC-DC converter 1 while also saving space around the first heatsink 12, which also serves as a conductive path.

[0133] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, a refrigerant pipe 23, which is a cooling passage through which the refrigerant circulates, is arranged inside the second heat sink 22 of the positive electrode side block 20.

[0134] This makes it possible to improve the cooling efficiency of the DC-DC converter 1 while saving space around the second heatsink 22, which also serves as a conductive path. Ultimately, this makes it possible to obtain a highly efficient DC-DC converter suitable for DC power supplies that handle large currents, and a DC power supply equipped with it.

[0135] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, the transformer rectifier block 11 has four sub-transformer rectifier blocks of the same configuration, the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D, and the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, as well as the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D are arranged left and right along the arrangement line AL of the rectifier element section 112.

[0136] This allows for the creation of an array structure of transformer and rectifier element mounting structures, each of which has two pairs of substructures containing the transformer and rectifier element mounting structures of the present invention. By minimizing the electrical paths between multiple substructures, it becomes possible to achieve an electrical path layout with excellent transmission efficiency. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices handling large currents, and a DC power supply device equipped with it.

[0137] Next, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. That is, the transformer rectifier block 11 has four sub-transformer rectifier blocks of the same configuration, from the first sub-transformer rectifier block 11A to the fourth sub-transformer rectifier block 11D. The pair of blocks, the first sub-transformer rectifier block 11A located above and the third sub-transformer rectifier block 11C located below, and the pair of blocks, the second sub-transformer rectifier block 11B located above and the fourth sub-transformer rectifier block 11D located below, are arranged with their mounting substrates 111 facing each other.

[0138] This allows for the creation of an array structure of transformer and rectifier element mounting structures, each of which has two pairs of substructures containing the transformer and rectifier element mounting structures of the present invention. By minimizing the electrical paths between multiple substructures, it becomes possible to achieve an electrical path layout with excellent transmission efficiency. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices handling large currents, and a DC power supply device equipped with it.

[0139] Furthermore, in the DC-DC converter 1 according to an embodiment of the present invention, the mounting structure of the transformer and rectifier elements in the transformer rectifier block 11 is configured as follows. Specifically, in the positive electrode block 20, connection terminals 21A, 21B, 21C, and 21D for electrically connecting to the center tap of the transformer 120 of the transformer rectifier block 11 are provided protruding from the surface of the second heat sink 22, thereby forming an air gap C between the transformer rectifier block 11 and the second heat sink 22 in the DC-DC converter 1.

[0140] As a result, the air gap C acts as an air cooling path, allowing the transformer rectifier block 11 and the second heat sink 22 to be air-cooled, thereby improving the cooling efficiency of these components. Consequently, it becomes possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices handling large currents, and a DC power supply device equipped with it.

[0141] As described above, the present invention provides a transformer and rectifier element mounting structure that is suitable for improving the conversion efficiency of the rectifier element, and consequently makes it possible to obtain a highly efficient DC-DC converter suitable for DC power supply devices that handle large currents.

[0142] (Variations, etc.) In the transformer and rectifier element mounting structure of the transformer and rectifier block 11 according to an embodiment of the present invention, the transformer 120 and the rectifier element section 112 are connected to busbars 131a and 131b that extend in a direction substantially perpendicular to the arrangement line AL of the rectifier element section 112, so that the electrical path connecting the coupling terminal 124a or coupling terminal 124b of the transformer to each of the plurality of rectifier elements constituting the rectifier element section 112 is formed in a direction substantially perpendicular to the arrangement line AL, which is a line segment along the arrangement of each of the plurality of rectifier elements in a plan view of the mounting substrate. However, the arrangement line AL, which is a line along the arrangement of each of the plurality of rectifier elements, is not limited to a line segment.

[0143] In other words, the mounting structure for the transformer and rectifier elements of the present invention is formed such that the electrical path connecting the transformer to each of the multiple rectifier elements mounted on the mounting substrate is formed as a straight line of substantially the same length for each of the multiple rectifier elements, and is formed in a direction substantially perpendicular to the arrangement line AL, which is a line along the arrangement of each of the multiple rectifier elements in a plan view of the mounting substrate. It is not limited by the specific arrangement of each of the multiple rectifier elements, in other words, the specific arrangement of the arrangement line AL.

[0144] For example, in the transformer and rectifier block 11 shown in Figure 7, the mounting structure of the transformer and rectifier elements is schematicly represented in Figure 12. The electrical path EP connecting the transformer 120 and each rectifier element of the rectifier element section 112 is formed as a straight line of substantially the same length, as each arrangement of the multiple rectifier elements 112x is formed substantially perpendicular to the arrangement line AL, which is a line segment. In Figure 12, the transformer 120 includes the arrangement line AL and is positioned relative to a plane perpendicular to the plane on which the figure is displayed, which corresponds to the plane along the mounting substrate.

[0145] On the other hand, the mounting structure of the transformer and rectifier elements can also be such that the arrangement of each of the multiple rectifier element sections 112x is in the shape of an arc centered on the connection terminal 122x of the transformer 120, as shown in the schematic diagram of Figure 13. Even in this case, the electrical path EP is formed as the radius of the arc, which is substantially perpendicular to the arrangement line AL, and is formed as a straight line of substantially the same length for each of the multiple rectifier element sections 112x. In Figure 13, the transformer 120 includes the arrangement line AL and is positioned relative to a curved surface with a cross-sectional arc shape that is perpendicular to the plane on which the figure is displayed, corresponding to the plane along the mounting substrate.

[0146] Furthermore, in the transformer and rectifier element mounting structure of the transformer rectifier block 11 according to the embodiment of the present invention, the electrical path connecting the coupling terminal 124a or coupling terminal 124b of the transformer to each of the plurality of rectifier elements constituting the rectifier element section 112 is formed in a direction substantially perpendicular to the arrangement line AL of the rectifier element section 112. However, as shown in the schematic diagram of Figure 13, the electrical path may be formed in a direction that intersects the arrangement line AL of the rectifier element section 112 at any angle.

[0147] Furthermore, in each of the above descriptions, the electrical paths connecting the transformer to each of the multiple rectifier elements constituting the rectifier element are formed in a direction that intersects with the array line AL, which is a line along the arrangement of each of the multiple rectifier elements in a plan view of the mounting substrate, and the transformer is positioned opposite the plane containing the array line AL. However, in the mounting structure of the transformer and rectifier elements of the present invention, it is sufficient that the electrical paths connecting the transformer to each of the multiple rectifier elements are formed as straight lines of substantially the same length for each of the multiple rectifier elements, and are not limited by the specific arrangement of the transformer and the multiple rectifier elements.

[0148] Next, in the transformer rectifier block 11 of the DC-DC converter 1 according to an embodiment of the present invention, as an example of the arrangement structure of the mounting structure of the transformer and rectifier elements of the present invention, the configuration is such that four sub-transformer rectifier blocks, which are examples of substructures of the present invention, are the first sub-transformer rectifier block 11A and the second sub-transformer rectifier block 11B, and the third sub-transformer rectifier block 11C and the fourth sub-transformer rectifier block 11D, which are four sub-transformer rectifier blocks of the same configuration, are arranged left and right along the arrangement line AL of the rectifier element section 112. However, the number of substructures arranged along the arrangement line AL of the rectifier elements may be one or any number.

[0149] Next, in the transformer rectifier block 11 of the DC-DC converter 1 according to the embodiment of the present invention, the busbars 131a and 131b in the transformer rectifier block 11 are configured such that, when the width dimension is defined as the dimension along the arrangement line AL of the rectifier element section 112, the width dimension on the rectifier element section 112 side (second side) is larger than the width dimension on the coupling terminal 124b side (first side) of the transformer 120. However, the dimension of the second side may be smaller than the dimension of the first side. This configuration is preferable when the width dimension of the coupling terminal 124b is larger than the arrangement line AL on the rectifier element section 112 side.

[0150] Next, in the transformer rectifier block 11 of the DC-DC converter 1 according to an embodiment of the present invention, the mounting substrate 111 of the circuit section 110 is composed of a first sub-mounting substrate 111A that is exposed on the surface side in the DC-DC converter 1 and a second sub-mounting substrate 111B that faces the second heat sink 22 of the positive electrode side block 20, but it may also be configured as a single mounting substrate.

[0151] Next, in the above description, the implementation structure of the transformer and rectifier element of the present invention was assumed to be incorporated into a DC-DC converter 1, which is the final stage of a DC power supply device. However, the present invention may also be a DC power supply unit that provides a DC output from the transformer and rectifier element. Therefore, the present invention may be incorporated into an AC-DC converter, or it may be implemented as an AC-DC converter.

[0152] Next, in the above description, the mounting structure of the transformer and rectifier element of the present invention is assumed to be configured as a synchronous full-wave rectifier circuit. However, the present invention may be configured for any rectifier circuit having a transformer and rectifier element, and is not limited by half-wave rectification or full-wave rectification, synchronous or asynchronous, or any other specific rectification method. Furthermore, it may be used in a normal transformer that does not use a center tap, or in a rectifier circuit that uses a diode as a rectifier element, and is not limited by the specific configuration, type, number, etc., of the transformer and rectifier element.

[0153] Next, in the above description, the mounting structure of the transformer and rectifier element of the present invention is assumed to be provided on the negative potential side in a DC-DC converter included in a DC power supply device, but it may also be provided on the positive potential side. In short, the present invention can be configured for any rectifier circuit having a transformer and rectifier element, and is not limited by the polarity of the wiring in the rectifier circuit.

[0154] As described above, embodiments of the present invention have been disclosed in the preceding description, but the present invention is not limited thereto.

[0155] In other words, without departing from the scope of the technical idea and objectives of the present invention, various changes can be made to the embodiments and each of the modifications described above in terms of mechanism, shape, material, quantity, position or arrangement, etc., and these are included in the present invention. [Explanation of Symbols]

[0156] 1 DC-DC converter 10 Negative electrode block 11. Transformer and rectifier block 11A, 310A First sub-transformer rectifier block 11B, 310B Second sub-transformer rectifier block 11C, 310C Third sub-transformer rectifier block 11D, 310D Fourth Sub-Transformer Rectifier Block 12. First heatsink 12x recess 13, 23 Refrigerant piping 14 First terminal busbar 14E, 24E end 15, 25, 135a, 135b Connecting members 20 Positive side block 21A, 21B, 21C, 21D, 21A~21D, 122x connection terminals 22. Second heatsink 22a First sub-heatsink 22b Second sub-heatsink 23a First sub-refrigerant piping 23b Second sub-refrigerant piping 24 Second terminal busbar 30a, 30b, 31a, 31b, 31c brackets 100 AC-DC converter 110 Circuit section 111, 313 Mounting board 111A First Sub-Mounting Board 111B Second Sub-Mounting Board 111F surface 111R back side 112, 112x rectifier element section 112A, 112B rectifier element group 112a Drain electrode 112b Source electrode 112c gate electrode 113, 319 Drive Circuit 113a First sub-drive circuit 113b Second Sub-Drive Circuit 114a, 114b, 320a, 320b Gate Wiring 117 Insulating material 120, 311 transformers 121 Primary coil 121B1, 312 Rectifier element 121a Primary side start end 121b Primary termination 122 Secondary coil 122a, 122b Starting end of secondary side 122c Secondary side intermediate end 123 PQ core 124a, 124b, 124c coupling terminal 130 Conductive part 130a First sub-conductive part 130b Second sub-conducting part 131a, 131b, 132a, 132b Busbar 133a, 133b connecting pins 134a, 134b via 136a, 136b connection pins 200 Primary DC-DC converter 300 Secondary DC-DC converter 311a1, 311b1 Primary end 311a2, 311b2 Secondary end 311c Center Tap 312A Positive side rectifier element 312B Negative electrode rectifier element

Claims

1. Transformer and The transformer is connected to a plurality of rectifier elements, The electrical path connecting the transformer and the plurality of rectifier elements is Each of the aforementioned plurality of rectifier elements is formed as a straight line of approximately the same length. Implementation structure of transformers and rectifier elements.

2. The aforementioned multiple rectifier elements are mounted on a substrate, The aforementioned electrical path is In a plan view of the aforementioned mounting substrate, the arrangement lines are formed in a direction that intersects with the arrangement lines of each of the plurality of rectifier elements. The transformer is positioned opposite the plane containing the arrangement lines, The mounting structure for the transformer and rectifier element according to claim 1.

3. The aforementioned arrangement lines are formed as line segments, The aforementioned electrical path is It is formed in a direction substantially perpendicular to the aforementioned arrangement line, The surface including the aforementioned arrangement lines is formed as a plane. The mounting structure for the transformer and rectifier element according to claim 2.

4. The transformer is adjacent to the mounting board via the electrical path. The mounting structure for the transformer and rectifier element according to claim 2.

5. The device includes a first heat sink that is electrically connected to the plurality of rectifier elements via the mounting substrate and extends along a direction substantially parallel to the arrangement lines to form a conductive path. The mounting structure for the transformer and rectifier element according to claim 3.

6. The transformer is provided with a second heat sink connected to the output side, which has a polarity different from the electrical path connecting the transformer and the plurality of rectifier elements, and which extends along a direction substantially parallel to the arrangement line to form a conductive path. The mounting structure for the transformer and rectifier element according to claim 3.

7. The transformer is mounted on the second heatsink. The mounting structure for the transformer and rectifier element according to claim 6.

8. The aforementioned mounting board is A first sub-mounting substrate fixed to one main surface of the first heat sink, The first heat sink has a second sub-mounting substrate fixed to the other main surface of the first heat sink, The plurality of rectifier elements are mounted on the first sub-mounting board and the second sub-mounting board, respectively. The mounting structure for the transformer and rectifier element according to claim 5.

9. The aforementioned electrical path is formed as a busbar that electrically connects the transformer and the plurality of rectifier elements. The dimensions of the sides of the busbar along the arrangement lines are such that the dimensions of the second side on the multiple rectifier element side are larger or smaller than the dimensions of the first side on the transformer side. The mounting structure for the transformer and rectifier element according to claim 5 or 6.

10. A cooling passage through which a refrigerant passes is provided inside the first heat sink, The mounting structure for the transformer and rectifier element according to claim 5.

11. A cooling passage through which a refrigerant passes is provided inside the second heat sink, The mounting structure for the transformer and rectifier element according to claim 6.

12. The transformer and rectifier element mounting structure described in claim 3 is provided as a substructure in multiple locations. The substructures are arranged along the arrangement lines. The arrangement structure of the mounting structure for transformers and rectifier elements.

13. The mounting structure of the transformer and rectifier element described in claim 2 is provided as a substructure, with at least one pair of these substructures. In the pair of substructures, each of the mounting substrates is arranged facing each other. The arrangement structure of the mounting structure for transformers and rectifier elements.

14. The array structure of the transformer and rectifier element mounting structure according to claim 12 or 13, The output from the mounting structure of the transformer and rectifier element is set to a DC output. DC power supply unit.

15. Having a plurality of DC power supply units as described in claim 14, The sum of the outputs of each of the DC power supply units is output. DC power supply.

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