Power Module

Abstract

We provide a power supply module that is easy to handle and can be implemented at a low cost. [Solution] The power module 1 mounted on a vehicle includes an AC / DC converter 11 that converts one of AC voltage and DC voltage to the other and outputs it, and a voltage converter 20 that converts a first voltage value of an input DC voltage to a DC voltage of a second voltage value. The voltage converter 20 includes a first converter 21 connected to the AC / DC converter 11 and a second converter 23 connected to the first converter 21 via a transformer 22. The power module 1 includes a first circuit board 81 on which the AC / DC converter 11 and the first converter 21 are provided, and a second circuit board 82 which is different from the first circuit board 81 and on which the second converter 23 is provided.

Description

Technical Field

[0001] The present invention relates to a power supply module mounted on a vehicle.

Background Art

[0002] For example, in an electric vehicle that runs using electric energy, such as an automobile equipped with a motor as a driving power source (hybrid electric vehicle (HEV), plug-in hybrid electric vehicle (PHEV), battery electric vehicle (BEV), fuel cell electric vehicle (FCEV), etc.), a battery for driving the motor is mounted. When charging this battery or when using the electric power stored in the battery, a power supply module that converts a DC voltage of a predetermined voltage value to a DC voltage of a desired voltage value is used. As a technology related to such a power supply module, for example, there is one described in Patent Document 1 whose citation is shown below.

[0003] Patent Document 1 describes a power conversion device (an example of a power supply module). This power conversion device includes an AC / DC converter and a DC / DC converter. The AC / DC converter is arranged on the upper surface side of the cooling chassis, and the DC / DC converter is arranged on the lower surface side of the cooling chassis.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the power conversion device described in Patent Document 1, the DC / DC converter located on the underside of the cooling chassis includes a circuit block that provides high-voltage DC output and a circuit block that provides low-voltage DC output, and these two circuit blocks are mounted on a single substrate. As a result, the substrate is large and difficult to handle in the manufacturing and inspection processes. Furthermore, since there is a difference in the current values ​​flowing through the circuit block that provides high-voltage DC output and the circuit block that provides low-voltage DC output, it is conceivable to change the layer configuration of the substrate and the thickness of the conductor layer according to the respective current values, but because it is a single substrate, it is necessary to match the specifications of the circuit block with the higher current value. Consequently, this is a factor that increases costs. For this reason, there is room for improvement in the power conversion device described in Patent Document 1 in order to simplify and reduce costs.

[0006] Therefore, there is a need for a power supply module that is easy to handle and can be implemented at a low cost. [Means for solving the problem]

[0007] The characteristic configuration of the power supply module according to the present invention is that it has an AC / DC conversion unit that converts one of AC voltage and DC voltage to the other and outputs it, and a voltage conversion unit that converts a first voltage value of an input DC voltage to a DC voltage of a second voltage value, and is a power supply module mounted on a vehicle, wherein the voltage conversion unit includes a first conversion unit connected to the AC / DC conversion unit and a second conversion unit connected to the first conversion unit via a transformer, and comprises a first circuit board on which the AC / DC conversion unit and the first conversion unit are provided, and a second circuit board different from the first circuit board on which the second conversion unit is provided.

[0008] With this characteristic configuration, the first substrate, which is equipped with an AC / DC converter and a first converter, and the second substrate, which is equipped with a second converter, can be constructed as separate components. Therefore, assembly and inspection of the first and second substrates can be easily performed, and handling in the manufacturing and inspection processes can be simplified. In addition, the layer configuration and conductor layer thickness of the first and second substrates can be set according to the specifications of the AC / DC converter, the first converter, and the second converter, respectively, making it possible to construct each substrate at a low cost. [Brief explanation of the drawing]

[0009] [Figure 1] This diagram shows the configuration of the circuitry provided in the power supply module. [Figure 2] This is a plan view of a power conversion device equipped with a power module. [Figure 3] This is a cross-sectional view taken along line III-III in Figure 2. [Figure 4] This is a diagram showing the connecting members. [Modes for carrying out the invention]

[0010] The power supply module according to the present invention is configured to be easily assembled to a power conversion device. The power supply module 1 of this embodiment will be described below. However, the power supply module 1 is not limited to the following embodiment and can be modified in various ways without departing from the spirit of the invention.

[0011] Figure 1 shows the circuit configuration of the power module 1. In this embodiment, the power module 1 is used to charge the traction battery B1, which stores the power used to drive the vehicle's traction motor M, and to utilize the power stored in the traction battery B1. Therefore, the power module 1 is mounted on the vehicle. The traction motor M is driven by the motor inverter MI based on the power stored in the traction battery B1.

[0012] The traction battery B1 is charged, for example, using commercial power. The use of the power stored in traction battery B1 includes, for example, generating power equivalent to that of commercial power using that power, or generating power corresponding to different voltage values ​​using that power. Specifically, generating power corresponding to different voltage values ​​refers to generating power to charge the low-voltage battery B2.

[0013] Therefore, the power module 1 charges the traction battery B1, which is mounted on the vehicle and stores power used to drive the vehicle's traction motor M using commercial power, generates power equivalent to commercial power using the power stored in the traction battery B1, and generates power to charge, for example, a low-voltage battery B2 using the power stored in the traction battery B1.

[0014] As shown in Figure 1, the power module 1 comprises a first filter 10, an AC / DC converter 11, a voltage converter 20, and a control unit 30. The voltage converter 20 includes a first converter 21, a transformer 22, a second converter 23, a second filter 24, a third converter 25, and a third filter 26.

[0015] The first filter 10 is installed on the inverter side and attenuates noise superimposed on the input voltage and current. The input voltage and current refer to the voltage and current from the commercial power supply supplied externally when charging the traction battery B1. On the other hand, when generating power equivalent to the commercial power supply from the power of the traction battery B1, these refer to the voltage and current from the AC / DC converter 11, which will be described later.

[0016] The AC / DC converter 11 converts one of the AC voltage and DC voltage to the other and outputs it. Converting one of the AC voltage and DC voltage to the other means that when charging the traction battery B1, it converts the AC voltage at the frequency of the commercial power supply (50Hz or 60Hz) to a DC voltage, and when generating power equivalent to the commercial power supply from the power of the traction battery B1, it means converting the DC voltage from the voltage conversion unit 20 (described later) to an AC voltage with the same frequency as the commercial power supply. Therefore, the AC / DC converter 11 converts an AC voltage to a DC voltage when it is input, and converts a DC voltage to an AC voltage when it is input.

[0017] The voltage conversion unit 20 converts the input DC voltage from a first voltage value to a DC voltage of a second voltage value. When charging the traction battery B1, the voltage conversion unit 20 converts the DC voltage from the AC / DC conversion unit 11 to a DC voltage with a voltage value suitable for charging the traction battery B1 and the low-voltage battery B2. On the other hand, when generating power equivalent to commercial power from the power of the traction battery B1, the voltage conversion unit 20 converts the DC voltage from the traction battery B1 to a DC voltage with a voltage suitable for conversion to AC voltage similar to that of commercial power.

[0018] The first converter unit 21 is connected to the AC / DC converter unit 11. When DC power is supplied from the AC / DC converter unit 11, the first converter unit 21 oscillates the DC power at a predetermined period and outputs it to the transformer 22. When AC power is supplied from the transformer 22, the first converter unit 21 converts the AC power into DC power and outputs it to the AC / DC converter unit 11. Here, "connection" in this embodiment means being electrically connected.

[0019] The second conversion unit 23 is connected to the first conversion unit 21 via the transformer 22. When AC power is supplied from the transformer 22, it converts the AC power to DC power and outputs it to the second filter 24. Also, when DC power is supplied from the traction battery B1 via the second filter 24, it converts the DC power to AC power and outputs it to the transformer 22.

[0020] The second filter 24 attenuates the noise superimposed on the input voltage and current. The input voltage and current refer to the voltage and current supplied from the second conversion unit 23 when charging the traveling battery B1. On the other hand, when generating power equivalent to commercial power from the power of the traveling battery B1, it refers to the voltage and current from the traveling battery B1.

[0021] The third conversion unit 25 is connected to the first conversion unit 21 via the transformer 22. The third conversion unit 25 converts it into a DC voltage with a third voltage value. The third conversion unit 25 converts the AC power from the transformer 22 into a DC voltage with a voltage suitable for charging the low-voltage battery B2 in both cases where the power supply module 1 charges the traveling battery B1 and where it uses the power of the traveling battery B1, and outputs it to the third filter 26.

[0022] The third filter 26 attenuates the noise superimposed on the input voltage and current. The input voltage and current refer to the voltage and current supplied from the third conversion unit 25.

[0023] The control unit 30 controls the driving of the AC-DC conversion unit 11, the voltage conversion unit 20, and the motor inverter MI. The AC-DC conversion unit 11, the voltage conversion unit 20, and the motor inverter MI are each configured with a plurality of switching elements, and the control unit 30 controls these switching elements by switching their open / closed states.

[0024] The AC / DC converter 11 and the first converter 21 are provided on the first substrate 81. That is, the AC / DC converter 11 and the first converter 21 are provided on a single substrate. The second converter 23 and the second filter 24 are provided on a second substrate 82, which is different from the first substrate 81. That is, the second converter 23 and the second filter 24 are separate from the first substrate 81 and are provided on a single substrate. Furthermore, the third converter 25 and the third filter 26 are provided on a third substrate 83, which is different from the first substrate 81 and the second substrate 82. That is, the third converter 25 and the third filter 26 are separate from both the first substrate 81 and the second substrate 82 and are provided on a single substrate. The control unit 30 is provided on a control substrate 84. This control substrate 84 is also a separate substrate from the first substrate 81, the second substrate 82, and the third substrate 83. Figure 1 also includes symbols to indicate each circuit board for easier understanding.

[0025] Figure 2 is a plan view of the power converter 100 with the power module 1 assembled. Figure 3 is a cross-sectional view taken along line III-III in Figure 2. As shown in Figure 2, the power converter 100 has a rectangular shape in plan view. In the following, the direction in which two of the four sides constituting this rectangular shape extend will be referred to as the X direction, and the direction perpendicular to the X direction will be referred to as the Y direction (an example of a "second direction"). Furthermore, the direction perpendicular to both the X and Y directions will be referred to as the Z direction (an example of a "first direction").

[0026] As shown in Figure 2, the first substrate 81, the second substrate 82, and the third substrate 83 are arranged around the transformer 22 such that they have at least non-overlapping portions when viewed in the Z direction along the thickness direction. In this embodiment, the transformer 22 is located in the central region with respect to the X and Y directions when viewed in the Z direction of the power converter 100. The state of having at least non-overlapping portions includes a state of not overlapping at all and a state of partially overlapping.

[0027] The first substrate 81 is mainly located on one side of the transformer 22 along the Y direction (Y1 side). In the example shown in Figure 2, the first substrate 81 partially overlaps with the transformer 22 along the Z direction. At this overlapping portion, the first substrate 81 is connected to terminals that are erected from the transformer 22 toward the first substrate 81. The second substrate 82 is located on one side of the transformer 22 along the X direction (X1 side) and the other side along the Y direction (Y2 side), with an L-shape when viewed in the Z direction. The third substrate 83 is located on the other side of the transformer 22 along the X direction (X2 side).

[0028] A space insulation section 90 is provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and the transformer 22 to suppress heat transfer between them. In this embodiment, as shown in Figure 2, a space insulation section 90 is provided between the second substrate 82 and the transformer 22, and a space insulation section 90 is provided between the third substrate 83 and the transformer 22. The space insulation section 90 is an air gap provided between the target substrate and the transformer 22 over a predetermined width. This width is preferably set so as to reduce the influence on the target substrate in relation to the heat of the transformer 22. Specifically, it is preferable to set it so that the thermal influence is below a predetermined amount.

[0029] Therefore, it is preferable to provide the space insulation section 90 between the transformer 22 and a region with a high heat generation density in at least one of the first substrate 81, the second substrate 82, and the third substrate 83. In this embodiment, as described above, the space insulation section 90 is provided between the second substrate 82 and the transformer 22, and between the third substrate 83 and the transformer 22. A high heat generation density means that the value obtained by dividing the amount of heat generated by the surface area of ​​the substrate is large. Therefore, in this embodiment, it is preferable to provide the space insulation section 90 between the transformer 22 and the transformer 22 and regions in the second substrate 82 and the third substrate 83 where the value obtained by dividing the amount of heat generated by the surface area of ​​the substrate is large. This reduces thermal stress on components provided on the second substrate 82 and the third substrate 83, even when heat is emitted from the transformer 22.

[0030] Furthermore, with the power module 1 of this embodiment, even if the output power is increased (specifically, changed from 3.3kW to 6.6kW), this can be accommodated by changing only the first circuit board 81 and the transformer 22. In this case, the size of the transformer 22 will increase, but since it can be placed using the area that was previously used as the space insulation section 90, it is possible to install the larger transformer 22.

[0031] As shown in Figure 3, the first substrate 81, the second substrate 82, and the third substrate 83 are arranged in a manner that differs from each other in terms of their positions along the Z direction when viewed in the Y direction. In this embodiment, the first substrate 81, the second substrate 82, and the third substrate 83 are each supported by a support 103 that rises from the bottom surface 102 of the housing 101. For ease of understanding, the support 103 supporting the first substrate 81 will be referred to as support 103A, the support 103 supporting the second substrate 82 as support 103B, and the support 103 supporting the third substrate 83 as support 103C. In this embodiment, of support 103A, support 103B, and support 103C, support 103A has the longest length along the Z direction, and support 103C has the shortest length along the Z direction. As a result, the first substrate 81, the second substrate 82, and the third substrate 83 are arranged at different distances (heights) from the bottom surface 102 of the housing 101. Here, the housing 101 refers to a case that houses the power module 1 and a cooling plate for cooling components mounted on the circuit board.

[0032] Furthermore, in this embodiment, the potential applied to the first substrate 81, the second substrate 82, and the third substrate 83 is highest for the first substrate 81 and lowest for the third substrate 83. Therefore, the first substrate 81, the second substrate 82, and the third substrate 83 are arranged in order of decreasing potential, starting from the side opposite the bottom surface 102 of the housing 101. The side opposite the bottom surface 102 is the Z2 side, which is the opposite side when viewed along the Z direction from each substrate, with the bottom surface 102 side being the Z1 side. Therefore, the first substrate 81, the second substrate 82, and the third substrate 83 are arranged in order of decreasing potential, starting from the Z2 side. As a result, for example, when conductive foreign matter is generated, it rolls down to the low potential side, thus providing superior insulating robustness. In addition, the Z1 side region 92 of the first substrate 81 can be made longer along the Z direction, making it possible to place relatively tall components (e.g., capacitor 40).

[0033] A cover (not shown) is provided on the Z2 side of the housing 101. When the cover is provided along the XY plane, the Z2 side of the third substrate 83 has more space than, for example, the Z2 side of the first substrate 81. Therefore, the control board 84 is positioned on the side opposite to the bottom surface 102 of at least one of the first substrate 81, second substrate 82, and third substrate 83 that is closest to the bottom surface 102. In other words, in this embodiment, the control board 84 is positioned on the Z2 side of the third substrate 83. In this embodiment, the control board 84 is positioned not only on the Z2 side of the third substrate 83 but also on the Z2 side of the second substrate 82.

[0034] When viewed from the control board 84 towards Z1, the distance along the Z direction is longer between the control board 84 and the third board 83 than between the control board 84 and the second board 82. Therefore, the control board 84 has relatively tall components 50, which are among the components provided on the control board 84, located in the region 91 facing the third board 83, which is one of the third boards 83 that is closest to the bottom surface 102 of the first board 81, the second board 82, and the third board 83. This makes it easier to secure space for the tall components 50, and eliminates the need for measures such as placing the tall components 50 horizontally to reduce their height. Consequently, it becomes possible to mount them without increasing the mounting area.

[0035] A first filter 10 is provided in the input stage when charging the traction battery B1. The first filter 10 is provided on a different board from the second board 82 and the third board 83 (in this embodiment, the board on the inverter side). A second filter 24 is provided on the second board 82 in the output stage when charging the traction battery B1. Furthermore, a third filter 26 is provided on the third board 83 in the output stage when charging the low-voltage battery B2. The second filter 24 and the third filter 26 are provided in areas on their respective boards where noise is relatively strong.

[0036] In this embodiment, to reduce the influence of noise in the first filter 10 on the second substrate 82 and the third substrate 83, the distance between the first filter 10 and the second filter 24 provided on the second substrate 82, and the distance between the first filter 10 and the third filter 26 provided on the third substrate 83, are set to be longer than the distance between the second filter 24 and the third filter 26. This makes it possible to reduce the influence of noise in the first filter 10 on the second substrate 82 and the third substrate 83, respectively.

[0037] The transformer 22, the second substrate 82, and the third substrate 83 are each connected using a connecting member 85. Figure 4 shows the connecting member 85 that connects the transformer 22 and the third substrate 83. As described above, the transformer 22 and the third substrate 83 are located at different positions along the Z-direction. Therefore, to compensate for this difference in position along the Z-direction, the connecting member 85 is connected to the transformer 22 via terminal 85A on one end and to the third substrate 83 via terminal 85B on the other end. The connecting member 85 also has an inclined portion 85C between terminals 85A and 85B that is inclined with respect to the Z-direction.

[0038] A circular hole 71 is provided on the terminal 85A side, and an elongated hole 72 is provided on the terminal 85B side. A spacer 86 is provided between terminal 85A and the transformer 22 along the Z direction. Terminal 85A and the transformer 22 are fastened and fixed together via bolts 87 inserted through the hole 71 and spacer 86. In addition, a spacer 88 is provided between terminal 85B and the third substrate 83 along the Z direction. Terminal 85B and the transformer 22 are fastened and fixed together via bolts 87 inserted through the elongated hole 72 and spacer 88. At this time, the difference in position (misalignment) between the transformer 22 and the third substrate 83 along the Z direction can be absorbed by the inclined portion 85C, and the difference in position (misalignment) between the transformer 22 and the third substrate 83 along the XY direction can be absorbed by the elongated hole 72. This makes it possible to properly connect the transformer 22 and the third substrate 83.

[0039] Figure 4 illustrates the connection between the transformer 22 and the third substrate 83, but the connection between the transformer 22 and the second substrate 82 is similar.

[0040] [Other Embodiments] Next, other embodiments of the power supply module 1 will be described.

[0041] In the above embodiment, the power supply module 1 was described as further comprising a voltage conversion unit 20 which includes a third conversion unit 25, and a third substrate 83 on which the third conversion unit 25 is provided. However, the power supply module 1 can also be configured such that the voltage conversion unit 20 does not include the third conversion unit 25. In this case, the third substrate 83 does not need to be provided.

[0042] In the above embodiment, the first substrate 81, the second substrate 82, and the third substrate 83 were described as being arranged around the transformer 22 such that they surround the transformer 22 with at least non-overlapping portions in the Z-direction view. However, the first substrate 81, the second substrate 82, and the third substrate 83 may be arranged around the transformer 22 such that at least two of the substrates completely overlap each other in the Z-direction view. Furthermore, the first substrate 81, the second substrate 82, and the third substrate 83 do not have to be arranged around the transformer 22 in the Z-direction view (they may be arranged so as not to surround the transformer 22).

[0043] In the above embodiment, the first substrate 81, the second substrate 82, and the third substrate 83 were described as being arranged in a manner in which their relative positions along the Z direction are different when viewed in the Y direction. However, at least two of the first substrate 81, the second substrate 82, and the third substrate 83 may be arranged in a manner in which their relative positions along the Z direction are the same when viewed in the Y direction.

[0044] In the above embodiment, the first substrate 81, the second substrate 82, and the third substrate 83 were described as being supported by a support 103 that rises from the bottom surface 102 of the housing 101. However, the first substrate 81, the second substrate 82, and the third substrate 83 may also be suspended and supported from the lid on the opposite side of the housing 101 from the bottom surface 102, or they may be supported by the inner wall of the housing 101. When the first substrate 81, the second substrate 82, and the third substrate 83 are suspended and supported from the lid, for example, the part that rises from the bottom surface 102 of the housing 101 to support the lid, the lid, and the part of the lid that supports the substrates 81, 82, and 83 correspond to the support 103. When the first substrate 81, the second substrate 82, and the third substrate 83 are supported by the inner wall of the housing 101, for example, the inner wall that rises from the bottom surface 102 of the housing 101 corresponds to the support 103.

[0045] In the above embodiment, the first substrate 81, the second substrate 82, and the third substrate 83 were described as being arranged in order of increasing potential from the side opposite the bottom surface 102 of the housing 101. However, the first substrate 81, the second substrate 82, and the third substrate 83 may also be arranged in order of decreasing potential from the side opposite the bottom surface 102 of the housing 101, or they may be arranged regardless of potential.

[0046] In the above embodiment, the control board 84 was described as being located on the side opposite to at least one of the first substrates 81, second substrate 82, and third substrate 83 that is closest to the bottom surface 102 of the housing 101. However, the control board 84 does not have to be located on the side opposite to at least one of the first substrates 81, second substrate 82, and third substrate 83 that is closest to the bottom surface 102 of the housing 101.

[0047] In the above embodiment, it was explained that a space insulation section 90 is provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and the transformer 22 to suppress heat transfer between them. However, it is not necessary to provide a space insulation section 90 between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and the transformer 22.

[0048] In the above embodiment, the space insulation portion 90 was described as being provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and a region with a high heat generation density. However, the space insulation portion 90 may be provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and a region other than the region with a high heat generation density.

[0049] In the above embodiment, the connecting member 85 that connects the transformer 22 to any two of the first substrate 81, second substrate 82, and third substrate 83 was described as having a circular hole 71 at one end and an elongated hole 72 at the other end. However, the connecting member 85 may have an elongated hole at one end or a circular hole at the other end. Furthermore, both ends may have circular holes, or both ends may have elongated holes. Moreover, the connecting member 85 is not limited to having a circular hole 71 at one end and an elongated hole 72 at the other end. The connecting member 85 is not particularly limited as long as it is capable of absorbing the misalignment between the transformer 22 and each of the two of the first substrate 81, second substrate 82, and third substrate 83 that are not fixed to the transformer 22, for example, a flexible busbar may be used. Alternatively, the transformer 22 may be connected to the first circuit board 81, the second circuit board 82, and the third circuit board 83, respectively, by connecting members 85.

[0050] In the above embodiment, it was explained that the distance between the first filter 10, which is provided on a substrate other than the second substrate 82 and the third substrate 83, and the second filter 24, which is provided on the second substrate 82, and the distance between the first filter 10 and the third filter 26, which is provided on the third substrate 83, are longer than the distance between the second filter 24 and the third filter 26. However, the distance between the first filter 10 and the second filter 24, which is provided on the second substrate 82, and the distance between the first filter 10 and the third filter 26, which is provided on the third substrate 83, may be the same as or shorter than the distance between the second filter 24 and the third filter 26.

[0051] In the above embodiment, the control board 84 was described as having a relatively tall tall component 50 among the components provided on the control board 84, located in a region 91 facing one of the first board 81, second board 82, and third board 83 of the control board 84 that is closest to the bottom surface 102 of the housing 101. However, the control board 84 does not necessarily have to have a relatively tall tall component 50 among the components provided on the control board 84 located in a region 91 facing one of the first board 81, second board 82, and third board 83 of the control board 84 that is closest to the bottom surface 102 of the housing 101.

[0052] [Summary of the above embodiment] The following describes the overview of the power supply module 1 as explained above.

[0053] (1) The power module 1 is mounted on a vehicle and includes an AC / DC converter 11 that converts one of AC voltage and DC voltage to the other and outputs it, and a voltage converter 20 that converts a first voltage value of an input DC voltage to a DC voltage of a second voltage value. The voltage converter 20 includes a first converter 21 connected to the AC / DC converter 11 and a second converter 23 connected to the first converter 21 via a transformer 22. The power module 1 includes a first circuit board 81 on which the AC / DC converter 11 and the first converter 21 are provided, and a second circuit board 82 which is different from the first circuit board 81 and on which the second converter 23 is provided.

[0054] According to this configuration, the first substrate 81, which is provided with the AC / DC conversion unit 11 and the first conversion unit 21 via the transformer 22, and the second substrate 82, which is provided with the second conversion unit 23, can be constructed as separate components. Therefore, assembly and inspection of the first substrate 81 and the second substrate 82 can be easily performed, and handling in the manufacturing and inspection processes can be simplified. In addition, the layer configuration and conductor layer thickness of the first substrate 81 and the second substrate 82 can be set according to the respective specifications of the AC / DC conversion unit 11, the first conversion unit 21, and the second conversion unit 23, making it possible to construct each substrate at a low cost. Furthermore, depending on the specifications, it is also possible to change one of the first substrate 81 or the second substrate 82 to accommodate the requirements, making it easy to create a series of power supply module 1 products.

[0055] (2) In the power supply module 1 described in (1), the voltage conversion unit 20 further includes a third conversion unit 25 which is connected to the first conversion unit 21 via a transformer 22 and converts the third voltage value into a DC voltage, and it is preferable that the third conversion unit 25 is provided and that the third board 83 is different from the first board 81 and the second board 82.

[0056] According to this configuration, the third substrate 83, on which the third conversion unit 25 is provided, can be provided separately from the first substrate 81 and the second substrate 82 described above. Therefore, it is possible to handle it simply, just like the first substrate 81 and the second substrate 82, and to construct the third substrate 83 at a low cost.

[0057] In the power supply module 1 described in (3)(2), it is preferable that the first substrate 81, the second substrate 82, and the third substrate 83 are arranged around the transformer 22 such that they have at least portions that do not overlap with each other when viewed in the Z direction (first direction) along the thickness direction.

[0058] In this configuration, the first board 81, the second board 82, and the third board 83 are each connected to the transformer 22. Therefore, by arranging them around the transformer 22, the first board 81, the second board 82, and the third board 83 can be connected to the transformer 22 in the shortest possible way. Furthermore, crossing of the wiring between them can be suppressed.

[0059] In the power supply module 1 described in (4)(3), it is preferable that the first substrate 81, the second substrate 82, and the third substrate 83 are arranged in such a manner that their positions along the Z direction are different when viewed in the Y direction (second direction) which is orthogonal to the Z direction.

[0060] With this configuration, since the positions in the Z-direction where the first substrate 81, the second substrate 82, and the third substrate 83 are each provided are different, the insulation distance between the first substrate 81, the second substrate 82, and the third substrate 83 can be ensured. Therefore, insulation measures can be implemented inexpensively.

[0061] In the power supply module 1 described in (5)(4), the first substrate 81, the second substrate 82, and the third substrate 83 are each supported by a support 103 that rises from the bottom surface 102 of the housing 101, and it is preferable that the first substrate 81, the second substrate 82, and the third substrate 83 are arranged in order of increasing potential from the opposite side of the bottom surface 102.

[0062] With this configuration, for example, when conductive foreign matter is generated, it rolls down to the lower potential side, resulting in superior insulating robustness. Therefore, insulating robustness against conductive foreign matter can be improved.

[0063] In the power supply module 1 described in (6)(4) or (5), the first substrate 81, the second substrate 82, and the third substrate 83 are each supported by a support 103 that rises from the bottom surface 102 of the housing 101, and it is preferable that a control board 84, which is provided with a control unit 30 that controls the driving of the AC / DC conversion unit 11 and the voltage conversion unit 20, is arranged on the side opposite to the bottom surface 102 of at least one of the first substrate 81, the second substrate 82, and the third substrate 83 that is closest to the bottom surface 102.

[0064] With this configuration, the control board 84 can be placed using the empty space on the opposite side of the board closest to the bottom surface 102 of the housing 101 among the first board 81, second board 82, and third board 83. Therefore, the size of the power module 1 can be prevented from increasing. In addition, the connection distances to each of the first board 81, second board 82, and third board 83 can be shortened, and the crossing with high-voltage lines (power lines with high applied voltage) can be reduced, thereby improving noise immunity.

[0065] In the power supply module 1 described in (7)(4) or (5), it is preferable that a space insulation section 90 is provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and the transformer 22 to suppress heat transfer between them.

[0066] This configuration reduces the impact of heat from the transformer 22 on the surrounding environment. Consequently, it reduces thermal stress on the components provided on the first substrate 81, the second substrate 82, and the third substrate 83.

[0067] In the power supply module 1 described in (8)(7), it is preferable that the space insulation section 90 is provided between at least one of the first substrate 81, the second substrate 82, and the third substrate 83 and a region with a high heat generation density.

[0068] With this configuration, since the spatial insulation section 90 is provided adjacent to the area with high heat density, the influence of heat on the surroundings can be reduced.

[0069] In the power supply module 1 described in (9)(4) or (5), it is preferable that the connecting member 85 that connects the transformer 22 to any two of the first board 81, second board 82, and third board 83 has a circular hole 71 at one end and an elongated hole 72 at the other end.

[0070] With this configuration, the elongated holes 72 can absorb any misalignment between the transformer 22 and any two of the first substrate 81, second substrate 82, and third substrate 83. Therefore, assembly can be easily performed.

[0071] In the power supply module 1 described in (10)(4) or (5), it is preferable that the distance between the first filter 10 provided on a substrate other than the second substrate 82 and the third substrate 83 and the second filter 24 provided on the second substrate 82, and the distance between the first filter 10 and the third filter 26 provided on the third substrate 83 are longer than the distance between the second filter 24 and the third filter 26.

[0072] This configuration makes it possible to reduce the impact of noise generated in the first filter 10 on the second substrate 82 and the third substrate 83, respectively.

[0073] In the power supply module 1 described in (11)(6), it is preferable that the control board 84 has a relatively tall tall component 50 among the components provided on the control board 84, which is located in a region facing one of the first board 81, second board 82, and third board 83 of the control board 84 that is closest to the bottom surface 102.

[0074] This configuration allows for securing space to mount the tall components 50 on the control board 84. Therefore, measures such as mounting the tall components 50 on their sides become unnecessary, preventing an increase in mounting area. [Industrial applicability]

[0075] The technology disclosed herein can be used in power modules installed in vehicles. [Explanation of Symbols]

[0076] 1: Power module, 10: First filter, 11: AC / DC converter, 20: Voltage converter, 21: First converter, 22: Transformer, 23: Second converter, 24: Second filter, 25: Third converter, 26: Third filter, 30: Control unit, 50: High-profile component, 71: Hole, 72: Slotted hole, 81: First substrate, 82: Second substrate, 83: Third substrate, 84: Control board, 85: Connecting member, 90: Space insulation section, 91 area, 101: Housing, 102: Bottom surface, 103: Support

Claims

1. A power supply module mounted on a vehicle, comprising: an AC / DC converter that converts one of AC voltage and DC voltage to the other and outputs it; and a voltage converter that converts a first voltage value of an input DC voltage to a second voltage value of DC voltage, The voltage conversion unit includes a first conversion unit connected to the AC / DC conversion unit and a second conversion unit connected to the first conversion unit via a transformer. The AC / DC conversion unit and the first conversion unit are provided on the first substrate, The second conversion unit is provided, and a second substrate different from the first substrate is provided, A power supply module equipped with the following features.

2. The voltage conversion unit further includes a third conversion unit which is connected to the first conversion unit via the transformer and converts the third voltage value into a DC voltage, The power supply module according to claim 1, further comprising the third conversion unit and a third substrate different from the first substrate and the second substrate.

3. The power supply module according to claim 2, wherein the first substrate, the second substrate, and the third substrate are arranged around the transformer such that they have at least portions that do not overlap with each other in a first viewing direction along the thickness direction.

4. The power supply module according to claim 3, wherein the first substrate, the second substrate, and the third substrate are arranged in such a manner that their positions along the first direction are different when viewed in a second direction perpendicular to the first direction.

5. The first substrate, the second substrate, and the third substrate are each supported by a support that rises from the bottom surface of the housing. The power supply module according to claim 4, wherein the first substrate, the second substrate, and the third substrate are arranged in order of increasing potential from the side opposite the bottom surface.

6. The first substrate, the second substrate, and the third substrate are each supported by a support that rises from the bottom surface of the housing. The power supply module according to claim 4 or 5, wherein a control board is provided on the side opposite to the bottom surface of at least one of the first board, the second board, and the third board that is closest to the bottom surface, and the control board is provided on the side that controls the driving of the AC / DC conversion unit and the voltage conversion unit.

7. The power supply module according to claim 4 or 5, wherein a space insulation portion is provided between at least one of the first substrate, the second substrate, and the third substrate and the transformer to suppress heat transfer between them.

8. The power supply module according to claim 7, wherein the space insulation portion is provided between at least one of the first substrate, the second substrate, and the third substrate and a region with a high heat density.

9. The power supply module according to claim 4 or 5, wherein the connecting member that connects the transformer to any two of the first substrate, the second substrate, and the third substrate has a circular hole at one end and an elongated hole at the other end.

10. The power supply module according to claim 4 or 5, wherein the distance between a first filter provided on a substrate other than the second substrate and the third substrate and a second filter provided on the second substrate, and the distance between the first filter and the third filter provided on the third substrate are longer than the distance between the second filter and the third filter.

11. The power supply module according to claim 6, wherein the control board is provided with a relatively tall tall component among the components provided on the control board, in a region facing one of the first board, the second board, and the third board of the control board that is closest to the bottom surface.

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