Power Converter

Abstract

This power converter is provided with: a metal housing that includes a base wall section and a side will section that rises from the base wall section so as to follow at least a portion of the outer edge of a first space that is a space above the base wall section; a circuit board disposed within the first space; a heat-generating component that is disposed within the first space and is electrically connected to the circuit board; a case that is disposed so as to be separated from the circuit board in a top view of the circuit board, has an opening section, and accommodates the heat-generating component; and a resin filling material that fills a space between the case and the heat-generating component and has a first surface that is exposed at the opening section. The heat-generating component includes a first terminal that protrudes in a direction that intersects a first plane that follows the first surface. The first terminal and the circuit board are electrically connected.

Description

[Technical Field]

[0001] The present disclosure relates to power converters. [Background technology]

[0002] A power converter is known in which a heat-generating component such as a coil component is housed in a housing space formed in the housing, and the housing space is filled with a resin filler (see, for example, JP 2017-212774 A (Patent Document 1)). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2017-212774 Summary of the Invention

[0004] A power converter according to the present disclosure includes a metal housing including a bottom wall and a sidewall extending from the bottom wall along at least a portion of the outer edge of a first space above the bottom wall, a circuit board disposed in the first space, a heat-generating component disposed in the first space and electrically connected to the circuit board, a case disposed apart from the circuit board in a top view of the circuit board and having an opening and housing the heat-generating component, and a resin filler filling the space between the case and the heat-generating component and having a first surface exposed at the opening. The heat-generating component includes a first terminal protruding in a direction intersecting a first plane along the first surface. The first terminal is electrically connected to the circuit board. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic perspective view showing the structure of the power converter according to the first embodiment. [Figure 2] FIG. 2 is a schematic perspective view showing the structure of the power converter according to the first embodiment. [Figure 3] FIG. 3 is a schematic perspective view showing the case of FIG. 1 with the filler material in the case omitted. [Figure 4] FIG. 4 is a schematic plan view showing the structure of the power converter according to the first embodiment. [Figure 5] FIG. 5 is a schematic exploded perspective view showing components of the power converter according to the first embodiment. [Figure 6] FIG. 6 is a schematic plan view showing a state in which the heat-generating component is housed in the case. [Figure 7] FIG. 7 is a schematic cross-sectional view showing a structure in the vicinity of the case of the power converter according to the first embodiment. [Figure 8] FIG. 8 is a schematic perspective view showing a state of connection between the terminals of the heat-generating component and the bus bar. [Figure 9] FIG. 9 is a schematic plan view showing an example of a connection between a bus bar and a terminal block. [Figure 10] FIG. 10 is a schematic plan view showing a state in which a heat-generating component is housed in a case according to the second embodiment. [Figure 11] FIG. 11 is a schematic plan view showing the structure of the power converter according to the third embodiment. [Figure 12] FIG. 12 is a schematic cross-sectional view showing the structure of the power converter in the vicinity of the case according to the fourth embodiment. [Figure 13] FIG. 13 is a schematic cross-sectional view showing the structure of the power converter in the vicinity of the case according to the fifth embodiment. [Figure 14] FIG. 14 is a schematic cross-sectional view showing the structure of the vicinity of the case of the power converter according to the sixth embodiment. [Figure 15] FIG. 15 is a schematic cross-sectional view showing the structure of the vicinity of the case of the power converter according to the seventh embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0006] [Problem to be solved by this disclosure] Generally, heat treatment is required to harden a resin filler that fills an accommodation space for accommodating a heat-generating component. In a structure in which an accommodation section that defines the accommodation space is connected to a circuit board as disclosed in Patent Document 1, the heat treatment for hardening the filler requires placing a large structure including areas other than the accommodation section in a heat treatment furnace or the like. As a result, there is a problem that it is difficult to improve production efficiency. One of the objectives of the present disclosure is to provide a power converter that enables improved production efficiency.

[0007] [Effects of this disclosure] According to the power converter of the present disclosure, production efficiency can be improved.

[0008] [Description of the embodiments of the present disclosure] First, embodiments of the present disclosure will be described. The power converter of the present disclosure includes a metal housing including a bottom wall and a side wall rising from the bottom wall so as to follow at least a portion of the outer edge of a first space above the bottom wall; a circuit board disposed in the first space; a heat-generating component disposed in the first space and electrically connected to the circuit board; a case disposed apart from the circuit board in a top view of the circuit board, having an opening, and housing the heat-generating component; and a resin filler filling the space between the case and the heat-generating component and having a first surface exposed at the opening. The heat-generating component includes a first terminal protruding in a direction intersecting a first plane along the first surface. The first terminal is electrically connected to the circuit board.

[0009] In the power converter of the present disclosure, the heat-generating components are housed in a case. This allows the heat-generating components to be housed in the case, and only the structure filled with filler can be placed in a heat treatment furnace or the like to harden the filler. As a result, it is possible to reduce the size of the structure to be placed in a heat treatment furnace or the like, thereby improving production efficiency. In this way, the power converter of the present disclosure allows for improved production efficiency.

[0010] In the above power converter, the case and the filler may be arranged so that the first plane intersects with a second plane that is along the bottom surface, which is the surface of the bottom wall portion facing the first space. This configuration reduces the space required for electrical connection between the first terminal of the heat-generating component that protrudes in a direction intersecting the first plane and the circuit board arranged on the bottom surface of the housing. As a result, it becomes easier to achieve a compact power converter.

[0011] In the power converter, the first terminal may extend from inside the filler through the first surface to the outside of the case. This configuration makes it easy to seal the entire portion (main body) of the heat-generating component other than the terminal with the filler.

[0012] The power converter may include a plurality of heat-generating components. The plurality of heat-generating components may be housed in a case. By housing a plurality of heat-generating components in a single case in this manner, it becomes easier to improve the production efficiency of the power converter and to reduce its size.

[0013] In the power converter, the case may include a metal partition member that divides the internal space of the case into a plurality of subspaces. At least one of the plurality of heat-generating components may be housed in one of the subspaces. By employing the metal partition member, it becomes possible to efficiently dissipate heat from the heat-generating component to the outside.

[0014] In the above power converter, the multiple heat-generating components may include a first coil component and a second coil component. The first coil component may include a first coil and a first core through which magnetic flux generated by current flowing through the first coil passes. The second coil component may include a second coil and a second core through which magnetic flux generated by current flowing through the second coil passes. In a top view of the circuit board, the direction of the magnetic flux passing through the first core may be different from the direction of the magnetic flux passing through the second core. By adjusting the orientation of the coil components in this way, it becomes easy to reduce the space required to install a case that houses the multiple heat-generating components. As a result, it becomes easy to miniaturize the power converter.

[0015] In the power converter, the heat-generating components may include a transformer and an inductor. By housing these components, which may be arranged closely together, in a single case, the space required for installing the case can be reduced. As a result, the power converter can be easily miniaturized.

[0016] In the power converter, the heat-generating components may include an inductor, a semiconductor device, and a capacitor. By housing these components, which may be arranged closely together, in a single case, the space required for installing the case can be reduced. As a result, the power converter can be easily miniaturized.

[0017] The power converter may further include a heat dissipation member disposed between the housing and the case so as to be in contact with the housing and the case. This configuration facilitates heat transfer from the case that houses the heat-generating components to the housing. As a result, it becomes easier to efficiently cool the heat-generating components.

[0018] In the power converter, the case may include heat dissipation fins, which makes it easier to efficiently cool heat-generating components housed in the case.

[0019] In the power converter, at least a portion of the outer wall surface of the case may surround at least a portion of the first space. This configuration allows the case to have the same function as the side wall of the housing. As a result, the structure of the power converter can be simplified.

[0020] In the power converter, the case may be arranged to divide the first space into a plurality of element spaces. With this configuration, the case can prevent noise generated from a component installed in one element space from reaching components installed in other element spaces.

[0021] The power converter may include a plurality of circuit boards. The case may be disposed between the plurality of circuit boards. With this configuration, the case can prevent noise generated by components mounted on one circuit board from reaching components mounted on other circuit boards.

[0022] [Details of the embodiment of the present invention] Next, embodiments of a power converter according to the present disclosure will be described below with reference to the drawings. In the following drawings, the same or corresponding parts are designated by the same reference numerals, and description thereof will not be repeated.

[0023] (Embodiment 1) First, a first embodiment of the present disclosure will be described. Fig. 1 is a schematic perspective view showing the structure of a power converter according to the first embodiment. Fig. 2 is a schematic perspective view showing the power converter according to the first embodiment as viewed from a different viewpoint than that of Fig. 1. Fig. 3 is a schematic perspective view showing Fig. 1 with the filler in the case omitted. Fig. 4 is a schematic plan view showing the structure of the power converter according to the first embodiment. Fig. 5 is a schematic exploded perspective view showing the components of the power converter according to the first embodiment disassembled.

[0024] 1 to 5, a power converter 1 according to the first embodiment includes a housing 10, a first circuit board 31, a second circuit board 32, a third circuit board 33, a first heat dissipation sheet 37, a second heat dissipation sheet 38, a third heat dissipation sheet 39, a first heat-generating component 51, a second heat-generating component 52, a third heat-generating component 53, a fourth heat-generating component 54, a case 40, and fillers 46B, 47B, 48B, and 49B. In this embodiment, the power converter 1 is a DC (Direct Current) DC converter. Note that the power converter of the present disclosure is not limited to a DC-DC converter and may be, for example, an inverter, a charger, or the like.

[0025] <Case structure> The housing 10 is made of metal. For example, an aluminum alloy can be used as the metal constituting the housing 10. The housing 10 includes a bottom wall 19, a first side wall 11, a second side wall 12, a third side wall 13, and a fourth side wall 14. The housing 10 has a rectangular parallelepiped shape. More specifically, it has a shape of a hollow rectangular parallelepiped with one face removed. The bottom wall 19 has a flat plate shape. The bottom wall 19 has a rectangular shape. In the first to seventh embodiments, the long side direction of the bottom wall 19 is the X-axis direction, the short side direction is the Y-axis direction, and the thickness direction of the bottom wall 19 is the Z-axis direction. The bottom wall 19 has a flat plate shape along the XY plane.

[0026] The first side wall 11, the second side wall 12, the third side wall 13, and the fourth side wall 14 rise from the bottom wall 19 along the outer edge of the first space 10A, which is the space above the bottom wall 19. The first side wall 11, the second side wall 12, the third side wall 13, and the fourth side wall 14 each have a flat plate-like shape. The first side wall 11, the second side wall 12, the third side wall 13, and the fourth side wall 14 each have a rectangular shape. The first side wall 11 and the second side wall 12 rise vertically from the outer edge corresponding to the short side of the bottom wall 19. The third side wall 13 and the fourth side wall 14 rise vertically from the outer edge corresponding to the long side of the bottom wall 19. The first side wall 11 and the second side wall 12 face each other across the first space 10A. The third side wall 13 and the fourth side wall 14 face each other across the first space 10A. The first side wall 11 and the second side wall 12 have a flat plate shape along the YZ plane. The third side wall 13 and the fourth side wall 14 have a flat plate shape along the XZ plane. The first side wall 11, the second side wall 12, the third side wall 13, and the fourth side wall 14 surround the first space 10A. In this embodiment, the bottom wall 19 and the first side wall 11, the second side wall 12, the third side wall 13, and the fourth side wall 14 are integral with each other, but in other embodiments, they may be separate bodies (separate parts).

[0027] <Circuit module structure> The first circuit board 31, the second circuit board 32, and the third circuit board 33 are housed in the first space 10A of the housing 10. Each of the first circuit board 31, the second circuit board 32, and the third circuit board 33 includes a board body made of an insulating material such as resin and a circuit pattern (not shown) made of a conductive material such as copper formed on the surface of the board body. The power converter 1 further includes devices 81-88, terminal blocks 71-74, and common mode choke coils 91 and 92. Devices 85, 86, 87, and 88 are mounted on the first circuit board 31 (on the circuit pattern of the first circuit board 31). Terminal blocks 73 and 74 are also mounted on the first circuit board 31 (on the circuit pattern of the first circuit board 31). Devices 81, 82, 83, and 84 are mounted on the second circuit board 32 (on the circuit pattern of the second circuit board 32). Terminal blocks 71 and 72 are further provided on second circuit board 32 (on the circuit pattern of second circuit board 32). Common mode choke coils 91 and 92 are further provided on second circuit board 32 (on the circuit pattern of second circuit board 32). First circuit board 31 and second circuit board 32, as well as devices 81-88, terminal blocks 71-74, and common mode choke coils 91 and 92 provided on first circuit board 31 and second circuit board 32, constitute a switching circuit module.

[0028] The power converter 1 further includes common mode choke coils 93 and 94. The common mode choke coil 93 and the common mode choke coil 94 are disposed on the third circuit board 33 (on the circuit pattern of the third circuit board 33). The third circuit board 33 and the common mode choke coils 93 and 94 disposed on the third circuit board 33 configure a noise filter circuit module.

[0029] <Structure of heat-generating component module> FIG. 6 is a schematic plan view showing a state in which heat-generating components are accommodated in a case. Referring to FIGS. 6 and 3, first heat-generating component 51 is an inductor (first inductor) in this embodiment. First heat-generating component 51 includes bobbin 51A, coil 51B, core 51C, and inductor terminals 51D and 51E as first terminals. Bobbin 51A has an annular shape. Coil 51B is wound around the outer circumferential surface of bobbin 51A. Core 51C penetrates annular bobbin 51A and functions as a core of coil 51B. Inductor terminals 51D and 51E are portions corresponding to both ends of a copper wire constituting coil 51B. Inductor terminals 51D and 51E are electrically and physically connected to coil 51B.

[0030] In this embodiment, the second heat-generating component 52 is a transformer. The second heat-generating component 52 includes a bobbin 52A, a coil 52B, a core 52C, and transformer terminals 52D, 52E, 52F, and 52G as first terminals. The bobbin 52A has an annular shape. The coil 52B is wound around the outer peripheral surface of the bobbin 52A. The core 52C penetrates the annular bobbin 52A and functions as a core of the coil 52B. The transformer terminals 52D, 52E, 52F, and 52G are electrically and physically connected to the coil 52B.

[0031] In this embodiment, third heat generating component 53 is an inductor (second inductor). Third heat generating component 53 includes bobbin 53A, coil 53B, core 53C, and inductor terminals 53D and 53E as first terminals. Bobbin 53A has an annular shape. Coil 53B is wound around the outer circumferential surface of bobbin 53A. Core 53C passes through annular bobbin 53A and functions as the core of coil 53B. Inductor terminals 53D and 53E are portions corresponding to both ends of the copper wire constituting coil 53B. Inductor terminals 53D and 53E are electrically and physically connected to coil 53B.

[0032] In this embodiment, the fourth heat-generating component 54 is a reactor. The reactor has a known structure, and detailed description thereof will be omitted here.

[0033] The first heat-generating component 51, the second heat-generating component 52, the third heat-generating component 53, and the fourth heat-generating component 54 are each a coil component including a coil. The first heat-generating component 51, which serves as the first coil component, includes a coil 51B, which serves as the first coil, and a core 51C, which serves as the first core through which magnetic flux generated by current flowing through the coil 51B passes. The second heat-generating component 52, which serves as the second coil component, includes a coil 52B, which serves as the second coil, and a core 52C, which serves as the second core through which magnetic flux generated by current flowing through the coil 52B passes. The third heat-generating component 53, which serves as the third coil component, includes a coil 53B, which serves as the third coil, and a core 53C, which serves as the third core through which magnetic flux generated by current flowing through the coil 53B passes. The magnetic flux directions of the coils 51B, 52B, and 53B are all in the Z-axis direction. The coils 51B, 52B, and 53B have the same magnetic flux direction. 6, when viewed in the Z-axis direction, the directions of the magnetic fluxes passing through cores 51C, 52C, and 53C are all the same as the X-axis direction. When viewed in the Z-axis direction, the directions of the magnetic fluxes passing through cores 51C, 52C, and 53C are the same.

[0034] The power converter 1 further includes bus bars 61, 62, 63, 64, 65, and 66 as conductive members. An inductor terminal 51E of the first heat-generating component 51 is connected to the bus bar 61. The bus bar 61 is connected to a terminal block 71. As a result, the first heat-generating component 51 is electrically connected to the second circuit board 32. An inductor terminal 51D of the first heat-generating component 51 is connected to the bus bar 62. The bus bar 62 is connected to a transformer terminal 52D of the second heat-generating component 52. As a result, the first heat-generating component 51 is electrically connected to the second heat-generating component 52. A transformer terminal 52E of the second heat-generating component 52 is connected to the bus bar 63. The bus bar 63 is connected to the terminal block 72. As a result, the second heat-generating component 52 is electrically connected to the second circuit board 32. A transformer terminal 52F of the second heat-generating component 52 is connected to the bus bar 64. The bus bar 64 is connected to the terminal block 73. As a result, second heat-generating component 52 is electrically connected to first circuit board 31. Transformer terminal 52G of second heat-generating component 52 is connected to bus bar 65. Bus bar 65 is connected to inductor terminal 53E of third heat-generating component 53. As a result, second heat-generating component 52 is electrically connected to third heat-generating component 53. Inductor terminal 53D of third heat-generating component 53 is connected to bus bar 66. Bus bar 66 is connected to terminal block 74. As a result, third heat-generating component 53 is electrically connected to first circuit board 31. Fourth heat-generating component 54 is electrically connected to first circuit board 31 via a conductive member (not shown).

[0035] Case 40 is disposed apart from first circuit board 31, second circuit board 32, and third circuit board 33 in a top view of first circuit board 31, second circuit board 32, and third circuit board 33 (as viewed in the Z-axis direction) (see FIG. 4 ). Case 40 is made of, for example, metal. Case 40 is a separate body from housing 10. Case 40 includes a main body 41 and metal partition members 42, 43, and 44 that divide the internal space of the case (the space surrounded by main body 41) into multiple subspaces. In this embodiment, these three partition members 42, 43, and 44 divide the internal space of case 40 into four subspaces: subspace 46, subspace 47, subspace 48, and subspace 49. Case 40 has multiple (four in this embodiment) openings 46A, 47A, 48A, and 49A. First heat-generating component 51 is housed in subspace 46. Second heat-generating component 52 is housed in partial space 47. Third heat-generating component 53 is housed in partial space 48. Fourth heat-generating component 54 is housed in partial space 49. In other words, one heat-generating component is housed in one partial space. Case 40, first heat-generating component 51, second heat-generating component 52, third heat-generating component 53, and fourth heat-generating component 54 constitute heat-generating component module 20.

[0036] <Arrangement of heat dissipation components> 5 and 7, the power converter 1 further includes heat dissipation sheets 37, 38, and 39 as heat dissipation members. The heat dissipation sheet 37 is located between the bottom wall 19 of the housing 10 and the first and second circuit boards 31 and 32, and is arranged so as to be in contact with the bottom wall 19 of the housing 10 and the first and second circuit boards 31 and 32. The heat dissipation sheet 38 is located between the bottom wall 19 of the housing 10 and the third circuit board 33, and is arranged so as to be in contact with the bottom wall 19 of the housing 10 and the third circuit board 33. The heat dissipation sheet 39 is located between the bottom wall 19 of the housing 10 and the case 40, and is arranged so as to be in contact with the bottom wall 19 of the housing 10 and the case 40.

[0037] <Filler placement> Referring to FIG. 1, power converter 1 includes filler 46B, filler 47B, filler 48B, and filler 49B. Filler 46B, filler 47B, filler 48B, and filler 49B are made of resin. FIG. 7 is a schematic cross-sectional view showing a structure near the case of the power converter according to the first embodiment. Referring to FIGS. 7 and 1, filler 46B fills the space (partial space 46) between case 40 and first heat-generating component 51 and has surface 46C as a first surface exposed at opening 46A. Filler 47B fills the space (partial space 47) between case 40 and second heat-generating component 52 and has surface 47C as a first surface exposed at opening 47A. Filler 48B fills the space (partial space 48) between case 40 and third heat-generating component 53 and has surface 48C as a first surface exposed at opening 48A. Filler 49B fills the space (partial space 49) between case 40 and fourth heat-generating component 54, and has surface 49C serving as a first surface exposed at opening 49A. Referring to Fig. 7, a plurality of heat dissipation fins 19B are formed on the surface of bottom wall 19 of housing 10 opposite the surface facing first space 10A. This makes it easy to dissipate heat from housing 10 to the outside.

[0038] 1, 4, and 7, inductor terminals 51D and 51E of first heat-generating component 51 protrude in a direction intersecting, or more specifically, in the Y-axis direction, which is a direction perpendicular to, the XZ plane that is a plane along surface 46C of filler 46B. Transformer terminals 52D, 52E, 52F, and 52G of second heat-generating component 52 protrude in a direction intersecting, or more specifically, in the Y-axis direction, which is a direction perpendicular to, the XZ plane that is a plane along surface 47C of filler 47B. Inductor terminals 53D and 53E of third heat-generating component 53 protrude in a direction intersecting, or more specifically, in the Y-axis direction, which is a direction perpendicular to, the XZ plane that is a plane along surface 47C of filler 47B. Referring to Figure 1, case 40 and fillers 46B, 47B, 48B, and 49B are arranged so that the XZ plane, which is a plane along surface 46C of filler 46B, surface 47C of filler 47B, surface 48C of filler 48B, and surface 49C of filler 49B, intersects (more specifically, is perpendicular to) a second plane (XY plane) that is along bottom surface 19A, which is the surface of bottom wall portion 19 facing first space 10A.

[0039] Inductor terminals 51D and 51E of first heat-generating component 51 extend from inside filler 46B through surface 46C to the outside of case 40. Transformer terminals 52D, 52E, 52F, and 52G of second heat-generating component 52 extend from inside filler 47B through surface 47C to the outside of case 40. Inductor terminals 53D and 53E of third heat-generating component 53 extend from inside filler 48B through surface 48C to the outside of case 40.

[0040] <Connection between the terminal of the heat-generating component and the bus bar> Next, a description will be given of a manner in which the terminals of the heat-generating component and the bus bar are connected. FIG. 8 is a schematic perspective view showing a manner in which the terminals of the heat-generating component and the bus bar are connected. Referring to FIG. 8, bus bar 62 is disposed in an end region to be connected to inductor terminal 51D of first heat-generating component 51, and includes a first region 621 extending in the Z-axis direction, which is a direction intersecting (more specifically, perpendicular to) the X-axis direction in which the portion other than the end region extends, a second region 622 extending in the Z-axis direction so as to face first region 621, and a third region 623 connecting first region 621 and second region 622. The distance between first region 621 and third region 623 corresponds to the thickness of inductor terminal 51D. By forming such a bent region including first region 621, second region 622, and third region 623 at the end of bus bar 62, it is possible to absorb errors during assembly in the direction in which inductor terminal 51D extends (the Y-axis direction). This results in an easy assembly of the power converter 1. In this embodiment, the above-described bent structure is employed for all ends of the bus bars that are connected to the terminals of the heat-generating components.

[0041] <Connection between busbar and terminal block> Next, a description will be given of a manner in which the bus bar and the terminal block are connected. Referring to FIG. 1, terminal block 71 includes screw 71A and main body 71B. Screw 71A is configured to be screwed into a threaded hole (not shown) formed in main body 71B and tightened to fix bus bar 61 to main body 71B. Here, bus bar 61 may have a structure capable of absorbing errors during assembly in the X-axis direction as described below. FIG. 9 is a schematic plan view showing an example of a manner in which the bus bar and the terminal block are connected. Main body 71B of terminal block 71 has a threaded hole 71C extending in the thickness direction (Z-axis direction) of second circuit board 32. Screw 71A is configured to be screwed into threaded hole 71C and tightened to fix bus bar 61 to main body 71B. Referring to FIG. 9, the end of bus bar 61 to be fixed to terminal block 71 is bent so as to extend in the X-axis direction. An elongated hole 61A is formed at the end of the bus bar 61, penetrating the bus bar 61 in the thickness direction (Z-axis direction) and extending in the X-axis direction. When viewed in the thickness direction (Z-axis direction) of the second circuit board 32, the elongated hole 61A is a hole that is larger in the extension direction (X-axis direction) of the bus bar 61 than in the width direction (Y-axis direction) of the bus bar 61. By forming such an elongated hole 61A in the bus bar 61, it is possible to absorb errors during assembly in the extension direction (X-axis direction) of the elongated hole 61A. As a result, it is possible to facilitate the assembly of the power converter 1.

[0042] <Effects of this embodiment> In the power converter 1 of this embodiment, the first heat-generating component 51, the second heat-generating component 52, the third heat-generating component 53, and the fourth heat-generating component 54 are housed in the case 40. As a result, only the structure in which the heat-generating components 51, 52, 53, and 54 are housed in the case 40 and filled with the fillers 46B, 47B, 48B, and 49B can be placed in a heat treatment furnace or the like to harden the fillers 46B, 47B, 48B, and 49B. As a result, the structure to be placed in the heat treatment furnace or the like can be made smaller, thereby improving production efficiency. In this way, the power converter 1 of this embodiment is a power converter that can improve production efficiency.

[0043] Furthermore, in power converter 1 of the present embodiment, case 40 and fillers 46B, 47B, 48B, 49B are arranged so that a plane (XZ plane) along surfaces 46C, 47C, 48C, 49C of fillers 46B, 47B, 48B, 49B intersects (is perpendicular to) a plane (XY plane) along bottom surface 19A. This makes it possible to reduce the space required for electrical connection between terminals 51D, 51E, 52D, 52E, 52F, 52G, 53D, 53E of heat-generating components 51, 52, 53 and circuit boards 31, 32 arranged on bottom surface 19A of housing 10.

[0044] Furthermore, in power converter 1 of the present embodiment, terminals 51D, 51E, 52D, 52E, 52F, 52G, 53D, and 53E of heat-generating components 51, 52, and 53 extend from the inside of fillers 46B, 47B, and 48B through surfaces 46C, 47C, and 48C to the outside of case 40. This makes it easy to seal the entire portions of heat-generating components 51, 52, and 53 except for terminals 51D, 51E, 52D, 52E, 52F, 52G, 53D, and 53E with fillers 46B, 47B, and 48B.

[0045] Furthermore, the power converter 1 of this embodiment accommodates a plurality of heat-generating components 51, 52, 53, 54 in one case 40, which makes it possible to improve production efficiency and easily reduce the size of the power converter.

[0046] Additionally, case 40 of the present embodiment includes metal partition members 42, 43, and 44 that divide the internal space into a plurality of (four) partial spaces 46, 47, 48, and 49. This allows heat from heat-generating components 51, 52, 53, and 54 to be efficiently released to the outside.

[0047] In addition, in power converter 1 of the present embodiment, first heat-generating component 51, second heat-generating component 52, third heat-generating component 53, and fourth heat-generating component 54 are an inductor, a transformer, an inductor, and a reactor, respectively. By accommodating these components, which may be arranged closely, within a single case 40, it is possible to reduce the space required to install case 40. Note that inductors, semiconductor devices, and capacitors may also be used as first heat-generating component 51, second heat-generating component 52, third heat-generating component 53, and fourth heat-generating component 54. By accommodating these components, which may be arranged closely, within a single case 40, it is possible to reduce the space required to install case 40.

[0048] Furthermore, the power converter 1 of this embodiment includes a third heat dissipation sheet 39 as a heat dissipation member arranged between the housing 10 and the case 40 so as to be in contact with the housing 10 and the case 40. This facilitates the transfer of heat from the case 40 that houses the heat-generating components 51, 52, 53, and 54 to the housing 10, and the heat-generating components 51, 52, 53, and 54 are efficiently cooled.

[0049] (Embodiment 2) Next, a second embodiment of the present disclosure will be described. Fig. 10 is a schematic plan view showing a state in which a heat-generating component is housed in a case according to the second embodiment. Fig. 10 corresponds to Fig. 6 of the first embodiment.

[0050] The power converter 1 of the second embodiment basically has the same structure and produces the same effects as the power converter 1 of the first embodiment. However, referring to Fig. 10 and Fig. 6, the second embodiment differs from the first embodiment in the structure of the heat-generating component module 20 included in the power converter 1.

[0051] 10 and 6, in heat-generating component module 20 of embodiment 2, the direction of magnetic flux passing through core 52C as the second core is the X-axis direction, as in embodiment 1, when viewed in the Z-axis direction. On the other hand, the direction of magnetic flux passing through core 51C as the first core and core 53C as the third core is the Y-axis direction, unlike embodiment 1. In other words, the direction of magnetic flux passing through core 52C is different from the direction of magnetic flux passing through core 51C and the direction of magnetic flux passing through core 53C. More specifically, the direction of magnetic flux passing through core 52C is perpendicular to the direction of magnetic flux passing through core 51C and the direction of magnetic flux passing through core 53C.

[0052] In this way, by adjusting the orientation of the heat generating components 51, 52, and 53, which are coil components, it becomes easy to reduce the space required to install a case that houses the plurality of heat generating components 51, 52, 53, and 54. As a result, the power converter 1 of this embodiment is a power conversion device that can be easily miniaturized.

[0053] (Embodiment 3) Next, a third embodiment, which is still another embodiment of the present disclosure, will be described. Fig. 11 is a schematic plan view showing the structure of a power converter in the third embodiment. Fig. 11 is a view corresponding to Fig. 4 of the first embodiment.

[0054] The power converter 1 of the third embodiment basically has the same structure and produces the same effects as the power converter 1 of the first embodiment. However, referring to Figures 11 and 4, the third embodiment differs from the first embodiment in the arrangement of the heat-generating component module 20, the noise filter circuit module, and the switching circuit module.

[0055] 11, case 40 is disposed so as to divide first space 10A into a plurality of element spaces, first element space 10B and second element space 10C. A noise filter circuit module including third circuit board 33 and common mode choke coils 93 and 94 mounted on third circuit board 33 is disposed in first element space 10B. A switching circuit module including first circuit board 31 and second circuit board 32, as well as devices 81 to 88 and common mode choke coils 91 and 92 mounted on first circuit board 31 and second circuit board 32 is disposed in second element space 10C. From another perspective, case 40 is disposed so as to be sandwiched between first circuit board 31 and second circuit board 32, which constitute the switching circuit module, and third circuit board 33, which constitutes the noise filter circuit module. This makes it possible for case 40 to prevent noise generated from components arranged in first element space 10B (components arranged on third circuit board 33) from reaching components arranged in second element space 10C (components arranged on first circuit board 31 and second circuit board 32).

[0056] (Fourth embodiment) Next, a fourth embodiment of the present disclosure will be described. Fig. 12 is a schematic cross-sectional view showing a structure in the vicinity of a case of a power converter according to the fourth embodiment. Fig. 12 is a diagram corresponding to Fig. 7 of the first embodiment.

[0057] The power converter 1 of the fourth embodiment basically has the same structure as the power converter 1 of the first embodiment and achieves the same effects. However, referring to Fig. 12 and Fig. 7, the fourth embodiment differs from the first embodiment in the structure of the case 40.

[0058] 12, case 40 of the fourth embodiment includes heat dissipation fins 45. Heat dissipation fins 45 are formed on a surface of case 40 opposite to the surface facing bottom wall 19 in the thickness direction (Z-axis direction) of bottom wall 19. In power converter 1 of the fourth embodiment in which case 40 including heat dissipation fins 45 is used, heat-generating components 51, 52, 53, and 54 housed in case 40 can be efficiently cooled.

[0059] (Embodiment 5) Next, a fifth embodiment, which is yet another embodiment of the present disclosure, will be described. Fig. 13 is a schematic cross-sectional view showing a structure in the vicinity of a case of a power converter according to the fifth embodiment. Fig. 13 is a diagram corresponding to Fig. 7 of the first embodiment.

[0060] The power converter 1 of the fifth embodiment basically has the same structure as the power converter 1 of the first embodiment and achieves the same effects. However, referring to Fig. 13 and Fig. 7, the fifth embodiment differs from the first embodiment in the structure of the housing 10 and the case 40.

[0061] 13, outer wall surface 40C, which is a part of the outer wall surface of case 40 of embodiment 5, surrounds a part of first space 10A. From another perspective, case 40 of embodiment 5 functions as a part of housing 10 (a side wall portion of housing 10). Housing 10 includes a plurality of heat dissipation fins 45. By employing such a configuration, power converter 1 of embodiment 5 is a power converter with a simplified structure.

[0062] (Embodiment 6) Next, a sixth embodiment, which is yet another embodiment of the present disclosure, will be described. Fig. 14 is a schematic cross-sectional view showing a structure in the vicinity of a case of a power converter according to the sixth embodiment. Fig. 14 is a diagram corresponding to Fig. 7 of the first embodiment.

[0063] The power converter 1 of the sixth embodiment basically has the same structure as the power converter 1 of the first embodiment and achieves the same effects. However, referring to Fig. 14 and Fig. 7, the sixth embodiment differs from the first embodiment in that the power converter 1 further includes a fourth circuit board 34.

[0064] Referring to FIG. 14 , power converter 1 according to the sixth embodiment further includes fourth circuit board 34. On fourth circuit board 34, there are mounted elements (not shown) for controlling first circuit board 31 and second circuit board 32, as well as a switching circuit module including devices 81-88 and common-mode choke coils 91 and 92 mounted on first circuit board 31 and second circuit board 32. Fourth circuit board 34 constitutes a control circuit module. At least a portion of inductor terminal 51E and bus bar 61 are located between fourth circuit board 34 and first circuit board 31. By adopting a structure in which multiple circuit boards at least partially overlap in the thickness direction (Z-axis direction) of bottom wall portion 19, first space 10A can be effectively utilized. As a result, power converter 1 according to the sixth embodiment can be easily made compact.

[0065] (Embodiment 7) Next, a seventh embodiment, which is yet another embodiment of the present disclosure, will be described. Fig. 15 is a schematic cross-sectional view showing a structure in the vicinity of a case of a power converter according to the seventh embodiment. Fig. 15 is a diagram corresponding to Fig. 14 of the sixth embodiment.

[0066] The power converter 1 of the seventh embodiment basically has the same structure as the power converter 1 of the sixth embodiment, and achieves the same effects. However, referring to Fig. 15 and Fig. 14, the seventh embodiment differs from the sixth embodiment in that the terminals and bus bars of the heat-generating components have an insulating coating.

[0067] 15 , inductor terminal 51E according to the seventh embodiment includes insulating coating 511 covering its surface. Bus bar 61 also includes insulating coating 611 covering its surface. Inclusion of insulating coatings 511, 611 on inductor terminal 51E and bus bar 61 makes it possible to reduce the insulation distance between inductor terminal 51E and bus bar 61 and other components. This makes it possible to reduce, for example, distance D1 between inductor terminal 51E and bus bar 61 and fourth circuit board 34, and distance D2 between inductor terminal 51E and bus bar 61 and device 81. As a result, power converter 1 according to the seventh embodiment is a power converter that can be easily made compact, particularly in the Z-axis direction.

[0068] It should be understood that the embodiments disclosed herein are illustrative in all respects and are not limiting in any respect. The scope of the present invention is defined not by the above description but by the claims, and it is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0069] REFERENCE SIGNS LIST 1 power converter, 10 housing, 10A first space, 10B first element space, 10C second element space, 11 first side wall portion, 12 second side wall portion, 13 third side wall portion, 14 fourth side wall portion, 19 bottom wall portion, 19A bottom surface, 19B heat dissipation fin, 20 heat-generating component module, 31 first circuit board, 32 second circuit board, 33 third circuit board, 34 fourth circuit board, 37 first heat dissipation sheet, 38 second heat dissipation sheet, 39 third heat dissipation sheet, 40 case, 40C outer wall surface, 41 main body, 42 partition member, 43 partition member 44 partition member, 45 heat dissipation fin, 46 partial space, 46A opening, 46B filling material, 46C surface, 47 partial space, 47A opening, 47B filling material, 47C surface, 48 Partial space, 48A opening, 48B filling material, 48C surface, 49 Partial space, 49A opening, 49B filling material, 49C surface, 51 First heat-generating component, 51A bobbin, 51B coil, 51C core, 51D inductor terminal, 51E inductor terminal, 52 Second heat-generating component, 52A bobbin, 52B coil, 52C core, 52D transformer terminal, 52E transformer terminal, 52F transformer terminal, 52G transformer terminal, 53 Third heat-generating component, 53A bobbin, 53B coil, 53C core, 53D inductor terminal, 53E inductor terminal, 54 Fourth heat-generating component, 61-66 bus bar, 61A slot, 71-74 terminal block, 71A screw, 71B body, 71C screw hole, 81-88 device, 91-94 Common mode choke coil, 511 insulating coating, 611 insulating coating, 621 first region, 622 second region, 623 third region, D1, D2 distance.

Claims

1. a metal housing including a bottom wall portion and a side wall portion rising from the bottom wall portion so as to follow at least a part of an outer edge of a first space that is a space above the bottom wall portion; a circuit board disposed in the first space; a heat-generating component disposed in the first space and electrically connected to the circuit board; a case that is disposed apart from the circuit board when viewed from above, has an opening, and accommodates the heat-generating component; a resin filler that fills a space between the case and the heat-generating component and has a first surface that is exposed at the opening, the heat generating component includes a first terminal protruding in a direction intersecting a first plane along the first surface, The first terminal and the circuit board are electrically connected to each other.

2. The power converter according to claim 1 , wherein the case and the filler are arranged so that the first plane intersects with a second plane that is along a bottom surface that is a surface of the bottom wall portion facing the first space.

3. The power converter according to claim 1 or 2, wherein the first terminal extends from inside the filler material through the first surface to outside the case.

4. the power converter includes a plurality of the heat-generating components, 3. The power converter according to claim 1, wherein the plurality of heat-generating components are housed in the case.

5. the case includes a metal partition member that divides an internal space of the case into a plurality of partial spaces, The power converter according to claim 4 , wherein at least one of the plurality of heat-generating components is accommodated in one of the partial spaces.

6. The plurality of heat generating components include: a first coil component; a second coil component, The first coil component is A first coil; a first core through which magnetic flux formed by a current flowing through the first coil passes; The second coil component is A second coil; a second core through which a magnetic flux formed by a current flowing through the second coil passes, The power converter according to claim 4 , wherein a direction of magnetic flux passing through the first core is different from a direction of magnetic flux passing through the second core when viewed from above the circuit board.

7. The power converter according to claim 4 , wherein the plurality of heat-generating components include a transformer and an inductor.

8. The power converter of claim 4 , wherein the plurality of heat-generating components include an inductor, a semiconductor device, and a capacitor.

9. 3. The power converter according to claim 1, further comprising a heat dissipation member disposed between the housing and the case so as to be in contact with the housing and the case.

10. The power converter according to claim 1 or 2, wherein the case includes heat dissipation fins.

11. The power converter according to claim 1 , wherein at least a portion of an outer wall surface of the case surrounds at least a portion of the first space.

12. The power converter according to claim 1 or 2, wherein the case is arranged to divide the first space into a plurality of element spaces.

13. the power converter includes a plurality of the circuit boards; The power converter according to claim 1 or 2, wherein the case is disposed so as to be sandwiched between the plurality of circuit boards.

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