Electrical equipment module and outdoor unit of air conditioner

Abstract

To restrain electromagnetic noise emission to the outside.SOLUTION: An electrical component module according to an embodiment comprises: a first board to which a power cable for supplying AC power from the outside is connected; a second board equipped with a converter circuit for performing power conversion of the AC power supplied via the first board; and a fixing plate equipped with the first board on one surface, and equipped with the second board on the other surface. The second board and the fixing plate each comprise openings penetrating each of them while the fixing plate is equipped with the second board. The openings are located outside a current loop formed by the converter circuit.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] An embodiment of the present invention relates to an electrical component module and an outdoor unit of an air conditioner. [Background technology]

[0002] In order to reduce the installation space required for outdoor units of air conditioners, miniaturization is also required for the electrical component modules that supply power to and control the air conditioner. Effective ways to miniaturize the electrical component module include reducing the area of ​​the circuit boards included in the electrical component module, or dividing the board into two boards, a main board and a power board, and placing them on the front and back of the fixing plate.

[0003] A known electrical component module for such an outdoor unit has a main board mounted on the front side of a mounting plate for fixing the boards and a power board mounted on the back side. This electrical component module is configured so that it is fixed to the outdoor unit with screws, with screw openings provided in the board and mounting plate. The module can be easily removed from the front side of the outdoor unit by removing the screws. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2019-163914 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the above-mentioned conventional technology, there is a problem in that the electromagnetic noise radiated from the power board, which is normally shielded by the fixing plate, can leak onto the main board through the openings provided for screw fastening. In particular, in large air conditioners in which a large current flows through the power board, the external impact of the electromagnetic noise radiated from the power board can become significant.

[0006] Therefore, the present disclosure proposes an electrical component module and an outdoor unit of an air conditioner that can suppress external electromagnetic noise radiation. [Means for solving the problem]

[0007] An electrical equipment module according to one aspect of the present disclosure includes a first board to which a power cable supplying AC power from an external source is connected, a second board on which a converter circuit is mounted that performs power conversion of the AC power supplied via the first board, and a fixed plate on one side of which the first board is mounted and the second board is mounted on the other side, and when the second board is mounted on the fixed plate, the second board and the fixed plate each have an opening passing therethrough, and the openings are located outside the current loop formed by the converter circuit. [Effects of the Invention]

[0008] It is possible to suppress external electromagnetic noise radiation. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of an outdoor unit according to an embodiment. [Figure 2] FIG. 2 is a perspective view of the outdoor unit according to the embodiment with the service panel removed. [Figure 3] FIG. 3 is a perspective view of the outdoor unit according to the embodiment, with the electrical component module removed from the machine compartment. [Figure 4] FIG. 4 is an exploded perspective view of the electrical component module and the cooler. [Figure 5] FIG. 5 is an explanatory diagram showing how the upper and lower frames are attached to the partition plate. [Figure 6] FIG. 6 is a vertical cross-sectional view of the electrical component module. [Figure 7] FIG. 7 is a cross-sectional view taken along line AA in FIG. [Figure 8] FIG. 8 is a plan view of the outdoor unit according to the embodiment with the top panel removed. [Figure 9]FIG. 9 is a right side view of the outdoor unit according to the embodiment with the right side panel removed. [Figure 10] FIG. 10 is a front view of the outdoor unit according to the embodiment with the main board removed from the machine chamber. [Figure 11] FIG. 11 is a front view of the main board. [Figure 12] FIG. 12 is a front view of the power board. [Figure 13] FIG. 13 is a front view illustrating an example of an electrode pattern on the surface of a converter circuit portion of a power board. [Figure 14] FIG. 14 is a front view illustrating an example of an electrode pattern on the back surface of a converter circuit portion of a power board. [Figure 15] FIG. 15 is an explanatory diagram illustrating the arrangement of electrode patterns on the front and back of the power board. [Figure 16] FIG. 16 is a circuit diagram illustrating an example of a converter circuit. [Figure 17] FIG. 17 is an explanatory diagram illustrating an example of an operation sequence in the converter circuit. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an electrical component module and an outdoor unit for an air conditioner according to an embodiment will be described with reference to the drawings. Components having the same functions in the embodiments will be assigned the same reference numerals, and duplicated descriptions will be omitted. Note that the electrical component module and outdoor unit for an air conditioner described in the following embodiments are merely examples and do not limit the embodiments. Furthermore, the following embodiments may be combined as appropriate within a consistent range.

[0011] 1 to 3, 8, and 9 show an outdoor unit 100 according to an embodiment. This outdoor unit 100 is installed outdoors in an air conditioner. The outdoor unit 100 and an indoor unit installed indoors are connected by refrigerant piping 30 to form a vapor compression refrigeration cycle.

[0012] For example, the outdoor unit 100 includes an outdoor heat exchanger 11 that exchanges heat between outdoor air and a refrigerant, a blower fan 11F, a compressor 12 that compresses the refrigerant, an accumulator 15 that separates the inflowing refrigerant into gas and liquid (see FIG. 8).The outdoor unit 100 also includes an oil separator that separates the lubricating oil from a mixture of the lubricating oil and the refrigerant, an expansion valve that expands the inflowing refrigerant and reduces its pressure to a predetermined level, and a four-way valve that switches between heating and cooling operation.

[0013] The indoor unit is equipped with an indoor heat exchanger that exchanges heat between the indoor air and the refrigerant, a blower fan, etc. Refrigerant piping 30 connects the outdoor heat exchanger 11, compressor 12, oil separator, expansion valve, accumulator 15, four-way valve, and indoor heat exchanger.

[0014] The housing 110 of the outdoor unit 100 includes a front panel 111, a service panel 112 on the right side of the front panel 111, a right side panel 113, a left side panel 114, a top panel 115, a back panel 116, and a bottom panel 117. A stand 118 is attached to the bottom panel 117 (see FIG. 9).

[0015] The housing 110 is divided in the left-right direction by a partition plate 119 so that the area behind the front panel 111 is the heat exchanger chamber 110A and the area behind the service panel 112 is the machine chamber 110B (see FIG. 8). The partition plate 119 forms part of the wall of the machine chamber 110B. The outdoor heat exchanger 11 and the blower fan 11F are disposed in the heat exchanger chamber 110A.

[0016] The machine room 110B also houses the refrigerant piping 30, the compressor 12, the expansion valve, the accumulator 15, the sub-accumulator 15A, the four-way valve, etc. The machine room 110B can be seen from the front side of the outdoor unit 100 by removing the service panel 112.

[0017] 200 is an electrical equipment module, and as shown in Figures 4 to 9, it comprises a fixed plate 210 that is placed in the machine room 110B so that its front faces the back surface of the service panel 112, an elongated upper frame 220 to which the upper part of the fixed plate 210 is attached, and an elongated lower frame 230 to which the lower part of the fixed plate 210 is attached.

[0018] The electrical equipment module 200 also includes a mounting bracket 240 that mounts the upper frame 220 to the partition plate 119, a mounting bracket 250 that mounts the lower frame 230 to the partition plate 119, a main board 260 (a first board of the present invention), and a power board 270 (a second board of the present invention). The main board 260 is a printed circuit board on which electronic components that form part of the control circuit and other electronic components are mounted. The power board 270 is a printed circuit board on which electronic components that form the remaining part of the control circuit and other electronic components, as well as a plurality of power devices 274 (described later), are mounted.

[0019] In this embodiment, the power board 270 is illustrated as being a double-sided board having electrode patterns 277a-277c and 278a-278c (see FIGS. 13 and 14) on both sides thereof for electrically connecting the power devices 274, but these electrode patterns may be arranged in one layer or in multiple layers (for example, three or more layers) on one side. Also, the electronic components mounted on the main board 260 and the power board 270 are merely examples and can be changed as appropriate.

[0020] As described above, the printed circuit board of the electrical component module 200 is divided into the main board 260 and the power board 270. The main board 260 is mounted on the fixed plate 210 so that the back surface 260b faces the front surface 211a of the fixed plate 210 (see FIG. 4). The power board 270 is mounted on the fixed plate 210 so that the back surface 270b faces the back surface 211b of the fixed plate 210 (see FIG. 4).

[0021] Reference numeral 300 denotes a cooler, which is attached to the upper frame 220 and the lower frame 230 so as to straddle the upper frame 220 and the lower frame 230 with the U-shaped bent portion 31 of the liquid side refrigerant pipe 30L attached (see FIG. 6).

[0022] The fixing plate 210 includes a main body 211, a reinforcing upper horizontal piece 212 bent at 90 degrees from the upper end of the main body 211 toward the back surface 211b, and an upper vertical piece 213 for attachment bent at 90 degrees upward from the rear end of the upper horizontal piece 212. The main body 211 has a main board 260 mounted on the front surface 211a and a power board 270 mounted on the back surface 211b.

[0023] The fixing plate 210 also includes a reinforcing lower horizontal piece 214 bent 90 degrees from the lower end of the main body 211 toward the front surface 211a, and a lower vertical piece 215 bent 90 degrees downward from the front end of the lower horizontal piece 214. Mounting portions 215a that protrude downward are formed on both ends of the lower vertical piece 215.

[0024] The upper frame 220 includes a vertical piece 221 that is screwed to the upper vertical piece 213 of the fixing plate 210, a reinforcing horizontal piece 222 that is bent backward at an angle of 90 degrees from the upper end of the vertical piece 221, and an attachment piece 223 that is bent forward at an angle of 45 degrees from the left end of the vertical piece 221. Reference numeral 224 denotes an end to which the cooler 300 is attached.

[0025] The lower frame 230 includes a lower vertical piece 231, an upper horizontal piece 232 bent backward at 90 degrees from the upper end of the lower vertical piece 231, a reinforcing upper vertical piece 233 bent upward at 90 degrees from the innermost end of the upper horizontal piece 232, and an attachment piece 234 bent forward at 45 degrees from the left end of the lower vertical piece 231. The lower vertical piece 231 is screwed to the lower vertical piece 215 of the fixing plate 210. A terminal board 400 is attached to the front side of the lower vertical piece 231. Reference numeral 235 denotes an end portion to which the cooler 300 is attached.

[0026] The cooler 300 is composed of an aluminum heat sink 310 that is thermally coupled to a plurality of power devices 274 (see FIG. 12) described later that are mounted on the surface 270a of the power board 270, a U-shaped bent portion 31 of the liquid side refrigerant piping 30L that is fitted into two grooves 311 with semicircular cross sections that are formed in the heat sink 310, and a sheet metal cover 320 that fixes the U-shaped bent portion 31 to the heat sink 310.

[0027] In addition to the groove 311, the heat sink 310 has a thick plate portion 312 against which the power device 274 is pressed and thermally coupled, and cover mounting portions 313 and 314 formed on both sides of the thick plate portion 312. The cover 320 has a central pressing portion 321 that presses the U-shaped bent portion 31 of the liquid-side refrigerant pipe 30L, a hook portion 322 bent from one end of the pressing portion 321, and a pressing portion 323 bent from the other end of the pressing portion 321 so as to face the hook portion 322.

[0028] 4, the power board 270 has an opening 276 that penetrates the board surface. Similarly, the fixing plate 210 has an opening 216 that penetrates the openings of the power board 270 when the power board 270 is mounted.

[0029] Fig. 10 is a front view of the outdoor unit 100 according to the embodiment with the main board 260 removed from the machine chamber 110B. As shown in Fig. 10, the fixing plate 210 has an opening 216a in the opening 216 of the fixing plate 210 at a position that overlaps with an opening 276a in the opening 276 of the power board 270 located at the back side when the power board 270 is mounted on the fixing plate 210.

[0030] Similarly, in the fixed plate 210, an opening 216b is provided vertically in the opening 216 of the fixed plate 210 at a position overlapping with the openings 276b to 276e in the opening 276 of the power board 270 located at the rear side. Furthermore, in the fixed plate 210, an opening 216c is provided vertically in the opening 216 of the fixed plate 210 at a position overlapping with the openings 276f to 276h in the opening 276 of the power board 270 located at the rear side. Furthermore, in the fixed plate 210, openings 216d, 216e, and 216f are provided in the opening 216 of the fixed plate 210 at positions overlapping with the openings 276i, 276j, and 276k in the opening 276 of the power board 270 located at the rear side, respectively. Specifically, the openings 276i and 216d, the openings 276j and 216e, and the openings 276k and 216f are provided at positions where they overlap each other.

[0031] Fig. 11 is a front view of the main board 260. As shown in Fig. 11, the front surface 260a of the main board 260 is mounted with electronic components that form part of the control circuit as described above, and other electronic components.

[0032] That is, the front surface 260a of the main board 260 is equipped with an AC input current detection / temperature detection circuit 261, an actuator drive circuit 262, a display setting circuit 263, a main control IC 264, an EMC filter circuit 265 (EMC: ElectroMagnetic Compatibility), a switching power supply circuit 266, an inrush current control circuit 267, a connector 268, etc.

[0033] The actuator drive circuit 262 is a circuit for driving actuators such as an expansion valve and a four-way valve. The display setting circuit 263 includes an LED lamp 263a as a display, and a DIP switch 263b and a button switch 263c as an operation unit. The EMC filter circuit 265 is a circuit for countering external noise and spontaneous noise, including a common mode choke coil 265a and a capacitor 265b. The switching power supply circuit 266 has a switching transformer 266a and a switching IC 266b.

[0034] The connector 268 is connected to a power cable that supplies AC power from the outside, and a power cable that supplies AC power that has passed through the main board 260 to the power board 270. The main board 260 outputs, for example, AC power from the outside that has been supplied through the connector 268 at the top to the power board 270 via a power cable connected to the connector 268 at the bottom after passing through an AC input current detection / temperature detection circuit 261, a switching power supply circuit 266, an inrush current control circuit 267, an EMC filter circuit 265, etc.

[0035] Reference numeral 260b denotes the back surface of main board 260. Reference numeral 260c denotes the top end of main board 260, 260d denotes the bottom end of main board 260, 260e denotes the left end of main board 260, and 260f denotes the right end of main board 260. This main board 260 is mounted on front surface 211a of main body part 211 of fixing plate 210 so that back surface 260b faces front surface 211a.

[0036] Fig. 12 is a front view of the power board 270. As shown in Fig. 12, electronic components including a plurality of power devices 274 (described below) that constitute the remaining portion of the control circuit are mounted on a surface 270a of the power board 270.

[0037] That is, a rectifying diode bridge circuit 271a and an IGBT element 271b (IGBT: Insulated Gate Bipolar Transistor) having a MOSFET incorporated in the gate portion of the bipolar transistor to reduce dynamic resistance are mounted on the surface 270a of the power board 270. The IGBT element 271b is an example of a switching element. Also mounted on the surface 270a of the power board 270 are an FRD element 271c (FRD: Fast Recovery Diode) for high-speed operation, a PFC coil 271d (PFC: Power Factor Correction) for power factor improvement, and an aluminum electrolytic capacitor 271e for high-power smoothing. The aluminum electrolytic capacitor 271e is an example of a smoothing capacitor.

[0038] The diode bridge circuit 271a, the IGBT element 271b, the FRD element 271c, the PFC coil 271d, and the aluminum electrolytic capacitor 271e constitute a converter circuit 271 that converts AC power supplied from an external source into DC power and outputs the DC power. Furthermore, on the surface 270a of the power board 270, an IPM element 272 (IPM: Intelligent Power Module) that constitutes an inverter circuit that converts the DC power supplied from the converter circuit 271 into AC power and outputs the AC power, a control circuit 273, and an output terminal 275 are also mounted.

[0039] The output terminal 275 is a terminal electrically connected to the IPM element 272 included in the power device 274, and outputs the AC power converted by the IPM element 272 to the motor of the compressor 12. The output terminal 275 includes three output terminals for outputting three-phase (U, V, W) AC power.

[0040] Reference numeral 270b denotes the back surface of power board 270. Reference numeral 270c denotes the top end of power board 270, 270d denotes the bottom end of power board 270, 270e denotes the left end of power board 270, and 270f denotes the right end of power board 270. Diode bridge circuit 271a, IGBT element 271b, FRD element 271c, and IPM element 272 are each power devices 274 that generate a lot of heat and are examples of heat-generating components. Diode bridge circuit 271a, IGBT element 271b, FRD element 271c, and IPM element 272 are mounted in a vertical array near left end 270e to facilitate cooling by cooler 300.

[0041] The power board 270 is mounted on the back surface 211b of the main body 211 of the fixing plate 210 so that the back surface 270b faces the back surface 211b. The cooler 300 faces the multiple power devices 274 and abuts against them.

[0042] The vertical size of the power board 270 is set according to the size of the vertical arrangement of the multiple power devices 274, and the PFC coil 271d, aluminum electrolytic capacitor 271e, control circuit 273, etc. are arranged so as to fit within that size. In this way, the vertical size of the power board 270 is set to a size slightly larger than the vertical size of the vertical arrangement of the multiple power devices 274. Note that the IGBT element 271b may be replaced with a MOSFET or the like.

[0043] The main board 260 is set to have a vertical size that corresponds to the vertical size of the power board 270. On the main board 260, an AC input current detection / temperature detection circuit 261, an actuator drive circuit 262, a display setting circuit 263, a main control IC 264, an EMC filter circuit 265, a switching power supply circuit 266, an inrush current control circuit 267, a connector 268, and the like are mounted so as to fit within the size.

[0044] To arrange the electrical equipment module 200 described above in the machine room 110B of the outdoor unit 100, first, a mounting bracket 240 having a slope 241 and a mounting bracket 250 having a slope 251 are attached to the partition plate 119 in advance. Then, to arrange the electrical equipment module 200, as shown in Fig. 5, the mounting pieces 223 of the upper frame 220 are screwed to the slope 241 of the mounting bracket 240, and the mounting pieces 234 of the lower frame 230 are screwed to the slope 251 of the mounting bracket 250. In this way, the upper frame 220 and the lower frame 230 are attached to the partition plate 119 in a horizontal position in a cantilevered manner.

[0045] Next, when arranging the electrical equipment module 200, as shown in Figure 6, the heat sink 310 of the cooler 300 is attached with screws B1 and B2 so that it straddles the end 224 of the vertical piece 221 of the upper frame 220 and the end 235 of the upper vertical piece 233 of the lower frame 230.

[0046] 7, when disposing the electrical equipment module 200, the U-shaped bent portion 31 of the liquid-side refrigerant pipe 30L is pressed against the groove 311 of the heat sink 310, and then the hook portion 322 of the cover 320 is engaged with one cover mounting portion 313 of the heat sink 310. Next, when disposing the electrical equipment module 200, the pressing portion 323 is pressed against the other cover mounting portion 314 of the heat sink 310, and the pressing portion 323 is fixed to the cover mounting portion 314 with screws B3 and B4. This work is performed with the rear panel 116 of the outdoor unit 100 removed.

[0047] As a result of the above, the cooler 300 is attached so as to straddle the end 224 of the upper frame 220 and the end 235 of the lower frame 230 and so that the thick plate portion 312 of the heat sink 310 faces the service panel 112 .

[0048] In addition, in arranging the electrical component module 200, the main board 260 is mounted on the front surface 211a of the main body 211 of the fixing plate 210, and the power board 270 is mounted on the back surface 211b. The fixing plate 210 on which the main board 260 and the power board 270 are mounted is attached with screws B5 and B6 so that its upper vertical piece 213 is aligned with the vertical piece 221 of the upper frame 220 and its lower vertical piece 215 is aligned with the lower vertical piece 231 of the lower frame 230. As a result, when the outdoor unit 100 is installed on a horizontal surface, the main board 260 and the power board 270 are arranged with their board surfaces parallel to the vertical direction in the machine chamber 110B of the outdoor unit 100. In addition, the fixing plate 210 functions as a sheet metal plate that forms the machine chamber 110B, and the power board 270 mounted on the back surface 211b of the fixing plate 210 is arranged within the machine chamber 110B.

[0049] At this time, the mounting pieces 223 of the upper frame 220 are attached to the partition plate 119 by mounting brackets 240, and the mounting pieces 234 of the lower frame 230 are attached to the partition plate 119 by mounting brackets 250. In addition, the end portion 224 of the upper frame 220 and the end portion 235 of the lower frame 230 are fixed to the U-shaped bent portion 31 of the liquid-side refrigerant pipe 30L by the cooler 300. Therefore, the fixing plate 210 is firmly fixed.

[0050] Furthermore, the multiple power devices 274 of the power board 270 are pressed against the thick plate portion 312 of the heat sink 310 of the cooler 300, and are thermally coupled thereto. Therefore, when the air conditioner starts operating, the heat generated by the power devices 274 is cooled by the cooler 300. If a heat dissipation grease with high thermal conductivity is applied to the thick plate portion 312 of the heat sink 310, the thermal coupling will be even better.

[0051] Furthermore, each package of the multiple power devices 274 has a through-hole (so-called a clearance hole) at a position corresponding to one of the openings 276a to 276k in the power board 270. Similarly, the heat sink 310 of the cooler 300, against which the power devices 274 are pressed and fixed, has screw holes corresponding to the through-holes of each package of the power devices 274. Therefore, when the multiple power devices 274 of the power board 270 are pressed against the thick plate portion 312 of the heat sink 310, the power devices 274 and the heat sink 310 are fastened together by inserting screws (not shown) into the screw holes via the openings 216a to 216f in the fixing plate 210, the openings 276a to 276k in the power board 270, and the through-holes in each package of the power devices 274 and tightening the screws.

[0052] After the electrical equipment module 200 has been installed in the machinery room 110B in the manner described above, plugs to which the required wiring is connected are connected to the connector 268 of the main board 260 of the electrical equipment module 200 and the output terminal 275 of the power board 270, and other required wiring is connected to the terminal board 400.

[0053] In the machine room 110B in which the electrical equipment module 200 is mounted, the lower vertical piece 231 of the lower frame 230 protrudes forward beyond the fixing plate 210 by the upper horizontal piece 232, and the terminal board 400 is mounted on the front surface 231a of the lower vertical piece 231, so that the terminal board 400 protrudes forward and is easily accessible. Also, in the machine room 110B, a large space SP is formed on the back surface 231b of the lower vertical piece 231, so that the lower frame 230 does not interfere with piping or the like arranged in the space SP.

[0054] In the machine chamber 110B, the multiple power devices 274 mounted on the power board 270 are thermally coupled to the cooler 300 on the rear surface 211b side of the fixing plate 210. At this time, the multiple power devices 274 are fastened by inserting and fastening screws (not shown) into the openings 216a to 216f in the fixing plate 210, the openings 276a to 276k in the power board 270, and the through-holes in each package of the power devices 274. Therefore, in the electrical component module 200, the multiple power devices 274 can be more firmly coupled to the heat sink 310 of the cooler 300. Furthermore, by loosening the screws (not shown) that fasten the power devices 274 and the screws B5 and B6, the fixing plate 210, the main board 260, and the power board 270 can be removed as a unit from the front of the machine chamber 110B without being obstructed by the cooler 300. In this way, maintenance of the main board 260 and the power board 270 can be easily performed in the machine room 110B.

[0055] Furthermore, the main board 260 is equipped on its front surface 260a with a display setting circuit 263 including LED lamps 263a, DIP switches 263b, button switches 263c, etc., and multiple connectors 268. Therefore, simply by removing the service panel 112 from the outdoor unit 100, it is easy to check and change the settings and operation of the air conditioner, and to switch circuit connections.

[0056] Next, a description will be given of the positional relationship between the openings 276a to 276k in the power board 270 and the electrode patterns that form conductors through which current flows in the converter circuit 271 of the power board 270. Fig. 13 is a front view illustrating the electrode patterns on the front surface 270a in the converter circuit 271 portion of the power board 270. Fig. 14 is a front view of the electrode patterns on the back surface 270b in the converter circuit 271 portion of the power board 270.

[0057] As shown in FIG. 13, for the converter circuit 271 of the power board 270, electrode patterns 277a, 277b, and 277c are formed on the surface 270a, which form a current loop (the dotted arrow in the figure indicates the portion that goes from the PFC coil 271d to the IGBT element 271b and the FRD element 271c) that runs from the diode bridge circuit 271a via the PFC coil 271d to the IGBT element 271b and the FRD element 271c and returns to the diode bridge circuit 271a. The electrode patterns 277a, 277b, and 277c on the surface 270a are connected to one of the two PFC coils 271d and one of the FRD elements 271c (for example, the upper side of the two PFC coils 271d and two FRD elements 271c arranged vertically in FIG. 13), and one of the two (four) IGBT elements 271b (for example, the upper side of the two IGBT elements 271b arranged vertically in FIG. 13).

[0058] Similarly, as shown in FIG. 14, for the converter circuit 271 of the power board 270, electrode patterns 278a, 278b, and 278c are formed on the back surface 270b, which form a current loop (the dotted arrow in the figure indicates the portion that goes from the PFC coil 271d to the IGBT element 271b and the FRD element 271c) that runs from the diode bridge circuit 271a via the PFC coil 271d to the IGBT element 271b and the FRD element 271c and returns to the diode bridge circuit 271a. The electrode patterns 278a, 278b, 278c on the back surface 270b are connected to the PFC coil 271d, the FRD element 271c, and the IGBT element 271b (for example, the lower side of the two PFC coils 271d, the two FRD elements 271c, and the two IGBT elements 271b arranged vertically in FIG. 14) that are not connected to the electrode patterns 277a, 277b, 277c on the front surface 270a.

[0059] As shown in FIGS. 13 and 14, openings 276a to 276k in power board 270 are located outside the current loops of electrode patterns 277a, 277b, 277c, 278a, 278b, and 278c formed on front and back surfaces 270a and 270b.

[0060] Inside the current loops of electrode patterns 277a, 277b, 277c, 278a, 278b, and 278c formed on front surface 270a and back surface 270b, electromagnetic noises reinforce each other according to Ampere's law, so that the electromagnetic noise inside the current loops is greater than that outside. Also, for example, in outdoor unit 100 of a large air conditioner, the current flowing through the current loops is large. For this reason, if there is an opening inside the current loop, electromagnetic noise generated by this current loop will leak out, causing a non-negligible impact on the outside.

[0061] However, in the power board 270, the openings 276a to 276k are located outside this current loop. Similarly, the positions of the openings 216a to 216f in the fixing plate 210 corresponding to the openings 276a to 276k in the power board 270 are also outside the current loop. Therefore, compared to when the openings are located inside the current loop, it is possible to prevent electromagnetic noise generated by the current loop from leaking from the openings to the front surface 211a of the fixing plate 210.

[0062] Furthermore, the direction orthogonal to the board surface corresponding to the inside of the current loop in the power board 270 is covered by the plate surface of the fixing plate 210 without holes. Therefore, electromagnetic noise generated from the inside of the current loop is blocked by the plate surface of the fixing plate 210, and hardly leaks out to the front surface 211a side of the fixing plate 210.

[0063] 15 is an explanatory diagram illustrating the arrangement of electrode patterns on the front and back surfaces of power board 270. As shown in Fig. 15, electrode patterns 277a to 277c formed on front surface 270a of power board 270 and electrode patterns 278a to 278c formed on back surface 270b of power board 270 may be arranged so that at least a portion (electrode patterns 277b, 278b in the illustrated example) of the electrode patterns overlap in a direction perpendicular to the board surface. By arranging the electrode patterns so that they overlap in a direction perpendicular to the board surface in this way, an increase in the board area can be prevented even when the pattern width is increased to accommodate a large current.

[0064] Fig. 16 is a circuit diagram showing an example of the converter circuit 271. Fig. 17 is an explanatory diagram illustrating an example of the operation sequence in the converter circuit 271.

[0065] 16, converter circuit 271 has a configuration in which a boost circuit including an IGBT element 271b, a PFC coil 271d, and an FRD element 271c of Q1 and a boost circuit including an IGBT element 271b, a PFC coil 271d, and an FRD element 271c of Q2 are connected in parallel to the output of diode bridge circuit 271a to which alternating current (AC) power is supplied. That is, converter circuit 271 has two sets of boost circuits.

[0066] In the converter circuit 271, the electrode patterns of the two sets of boost circuits are separately arranged on the front surface 270a and the back surface 270b of the power board 270. For example, the boost circuit of the IGBT element 271b of Q1 may be formed as electrode patterns 277a to 277c on the front surface 270a, and the boost circuit of the IGBT element 271b of Q2 may be formed as electrode patterns 278a to 278c on the back surface 270b.

[0067] Here, the current of the boost circuit in the IGBT element 271b of Q1 is LA, and the ripple current is ΔI LA Let the current of the boost circuit in the IGBT element 271b of Q2 be LB, and the ripple current be ΔI LB The combined current of the two boost circuits is LA+LB, and the ripple current in this combined current is ΔI LA +ΔI LB In this case, for example, a current LA flows through the electrode pattern 277b and a current LB flows through the electrode pattern 278b shown in FIG.

[0068] Here, the control circuit 273 controls the switching operations of Q1 and Q2 so that the currents LA and LB change periodically and the timings at which the currents reach their peaks are shifted.

[0069] 17, the control circuit 273 operates to shift the ON / OFF switching timing (switching phase) of Q1 and Q2 by 180°, so that the currents LA and LB flow through the electrode patterns 277b and 278b with a phase shift of 180°.

[0070] In this way, by shifting the peak timings of the periodically changing currents LA and LB, the peaks of the electromagnetic noise generated in the two electrode patterns 277b and 278b do not overlap with each other. Also, in the electrical component module 200, by shifting the phases of the currents LA and LB by 180°, the ripple current (ΔI LA +ΔI LB ) can be reduced, thereby suppressing electromagnetic noise caused by ripple current. Furthermore, in the electrical component module 200, the timing at which the heat generation peaks of the electrode patterns 277b and 278b can be separated sufficiently. This makes it possible to suppress temperature increases in the electrode patterns 277b and 278b even when the electrode patterns 277b and 278b are arranged so as to overlap in a direction perpendicular to the board surface.

[0071] In this embodiment, an interleaved circuit configuration in which two sets of boost circuits using switching elements (Q1, Q2) are prepared and the switching phases are shifted by 180° is exemplified as an example of the converter circuit 271. However, the circuit configuration of the converter circuit 271 is not limited to the interleaved configuration described above. For example, a bridgeless circuit configuration including multiple switching elements may also be used.

[0072] As described above, electrical component module 200 has main board 260 to which a power cable that supplies AC power from an external source is connected, power board 270 on which converter circuit 271 that converts the AC power supplied via main board 260 is mounted, and fixing plate 210 on one side of which main board 260 is mounted and on the other side of which power board 270 is mounted. When power board 270 is mounted on fixing plate 210 of electrical component module 200, power board 270 and fixing plate 210 each have openings 216a-216f and 276a-276k that pass through them, and these openings are located outside the current loop formed by converter circuit 271.

[0073] According to Ampere's law, electromagnetic noise generated by the current loop formed by the converter circuit 271 is stronger inside the current loop than outside the current loop, and is sufficiently weak outside the current loop. Therefore, in the electrical component module 200, by positioning the opening in the fixing plate 210 outside the current loop formed by the converter circuit 271, it is possible to prevent electromagnetic noise generated by the converter circuit 271 from leaking out from the opening to one side of the fixing plate 210. Therefore, in the electrical component module 200, it is possible to sufficiently minimize the influence of electromagnetic noise emitted from the converter circuit 271 on the main board 260, which is disposed on the outside across the power board 270 and the fixing plate 210, and the power cable connected to the main board 260.

[0074] Furthermore, in electrical component module 200, power board 270 has electrode patterns arranged on multiple layers, and electrode patterns 277a-277c and 278a-278c forming converter circuit 271 are arranged on at least the first and second layers of the multiple layers. The electrode pattern arranged on the first layer (the first pattern of the present invention, for example, electrode pattern 277b) and the electrode pattern arranged on the second layer (the second pattern of the present invention, for example, electrode pattern 278b) are arranged so that at least a portion of them overlap in a direction perpendicular to the board surface. In this way, in electrical component module 200, by arranging the electrode patterns so that they overlap in a direction perpendicular to the board surface, it is possible to prevent the board area from becoming larger.

[0075] In addition, in electrical component module 200, currents LA and LB flowing through two electrode patterns (e.g., electrode patterns 277b and 278b) arranged to overlap in a direction perpendicular to the board surface vary periodically, and the timing of their peak currents is offset from one another. This prevents the peaks of electromagnetic noise generated by two electrode patterns arranged to overlap in a direction perpendicular to the board surface from overlapping, further reducing the impact of electromagnetic noise emitted from converter circuit 271. Furthermore, the timing of the peaks of heat generation in the two electrode patterns can be prevented from overlapping, thereby reducing the temperature rise in the two electrode patterns even when the two electrode patterns are arranged to overlap in a direction perpendicular to the board surface.

[0076] In the electrical component module 200, the electrical components that form the converter circuit 271 include a plurality of IGBT elements 271b, which are switching elements. The currents LA and LB flowing through the two electrode patterns that are arranged to overlap in a direction perpendicular to the board surface are adjusted by the plurality of switching elements so that they flow with a phase difference of 180°. This makes it possible for the electrical component module 200 to suppress the peak of electromagnetic noise generated in the two electrode patterns that are arranged to overlap in a direction perpendicular to the board surface, and further to suppress the impact of electromagnetic noise emitted from the converter circuit 271. In addition, in the electrical component module 200, the ripple (ΔI LA +ΔI LB Furthermore, the timings at which the heat generation peaks in the two electrode patterns can be separated sufficiently, and even when the two electrode patterns are arranged so as to overlap in a direction perpendicular to the substrate surface, the temperature rise in the two electrode patterns can be further suppressed.

[0077] In addition, in the electrical component module 200, the power board 270 is mounted with its back surface 270b facing the fixing plate 210, and the electrical components of the power board 270 include heat-generating components (diode bridge circuit 271a, IGBT element 271b, FRD element 271c, IPM element 272, etc.). These heat-generating components are arranged on the front surface (front surface 270a) of the power board 270. This prevents heat from building up in the electrical component module 200 compared to when the heat-generating components are arranged on the back surface 270b side facing the fixing plate 210, and allows the heat-generating components to be cooled more efficiently.

[0078] Furthermore, the electrical component module 200 includes a cooler 300 that is thermally coupled to the heat-generating components of the power board 270. This allows the electrical component module 200 to efficiently dissipate heat generated by the heat-generating components of the power board 270 via the cooler 300.

[0079] In addition, in electrical component module 200, heat-generating components of power board 270 and cooler 300 are screwed together via openings 216a-216f, 276a-276k that penetrate power board 270 and fixing plate 210, respectively. This allows electrical component module 200 to fix heat-generating components of power board 270 to cooler 300 from the front side while preventing electromagnetic noise from leaking out of the openings. In addition, in electrical component module 200, fixing the heat-generating components to cooler 300 in this manner prevents misalignment between the heat-generating components and cooler 300 due to vibrations caused by, for example, rotation of blower fan 11F.

[0080] Furthermore, the electrical component module 200 is a board attached to the outdoor unit 100 of the air conditioner, the outdoor unit 100 having a machine room 110B, and the fixing plate 210 is a plate material that forms the machine room 110B of the outdoor unit 100. The power board 270 in the electrical component module 200 is arranged inside the machine room 110B. This makes it possible to prevent electromagnetic noise generated by the power board 270 arranged inside the machine room 110B from leaking outside the machine room 110B in the outdoor unit 100. [Explanation of symbols]

[0081] 11...Outdoor heat exchanger 11F...Ventilation fan 12...Compressor 14...Expansion valve 15...Accumulator 15A...Sub-accumulator 30...Refrigerant piping 30L...Liquid refrigerant piping 31...U-shaped bending part 100...Outdoor unit 110…Housing 110A…Heat exchange room 110B…Machine room 111...Front panel 112...Service panel 113...Right side panel 114...Left side panel 115...Top panel 116…Rear panel 117...Bottom panel 118...Stand 119...Partition board 200...Electrical equipment module 210…Fixing plate 211...Main body 211a...Front 211b…Back side 215a...Mounting part 216, 276...Opening 216a~216f, 276a~276k...Aperture 220...Upper frame 260...Main board 260a…Front 260b…Back side 261...AC input current detection / temperature detection circuit 262...Actuator drive circuit 263…Display setting circuit 263a...LED lamp 263b...DIP switch 263c...button switch 264...Main control IC 265...EMC filter circuit 265a...Common mode choke coil 265b...Capacitor 266...Switching power supply circuit 266a...Switching transformer 266b...Switching IC 267...Inrush current control circuit 268...Connector 270...Power board 271...Converter circuit 271a...Diode bridge circuit 271b...IGBT element 271c...FRD element 271d...PFC coil 271e...Aluminum electrolytic capacitor 272...IPM element 273...Control circuit 274...Power devices 275...Output terminal 277a~278c...Electrode patterns 300...Cooler 310...heat sink 311...Groove 312…Thick plate section 313, 314...Cover mounting part 320...Cover 321, 323...Presser section 322...Hook part 400...Terminal board B1~B6...Screws LA, LB…Current SP…Space

Claims

1. a first substrate to which a power cable for supplying AC power from an external source is connected; a second substrate on which a converter circuit is mounted that performs power conversion of AC power supplied via the first substrate; a fixing plate on one surface of which the first substrate is mounted and on the other surface of which the second substrate is mounted; When the second substrate is mounted on the fixing plate, the second substrate and the fixing plate each have an opening passing therethrough, the opening is located outside a current loop formed by the converter circuit; An electrical equipment module characterized by:

2. The second substrate has patterns arranged in a plurality of layers, and the patterns forming the converter circuit are arranged in at least a first layer and a second layer of the plurality of layers, and the first pattern arranged in the first layer and the second pattern arranged in the second layer are arranged so that at least a portion of the first pattern overlaps in a direction perpendicular to the substrate surface.

2. The electrical equipment module according to claim 1.

3. The currents flowing through the first pattern and the second pattern change periodically, and the timings at which the currents reach their peaks are different from each other.

3. The electrical equipment module according to claim 2.

4. the electrical components forming the converter circuit include a plurality of switching elements; The currents flowing in the first pattern and the second pattern are adjusted by the plurality of switching elements so as to flow with a phase difference of 180°.

4. The electrical equipment module according to claim 3.

5. The second substrate is The back surface is mounted so as to face the fixed plate, the electrical components include heat-generating components; the heat generating component is disposed on the surface of the second substrate; 5. The electrical equipment module according to claim 4.

6. a cooler thermally coupled to the heat-generating component; 6. The electrical equipment module according to claim 5.

7. The heat generating component and the cooler are screwed together through the opening.

7. The electrical equipment module according to claim 6.

8. An outdoor unit of an air conditioner to which the electrical equipment module according to any one of claims 1 to 7 is attached, The outdoor unit has a machine room, the fixing plate is a plate member that forms the machine chamber of the outdoor unit, The second substrate is disposed in the machine chamber. An outdoor unit of an air conditioner characterized by the above.

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