Electrical components, and methods for manufacturing electrical components

Abstract

To provide an electric part which can secure a level that an amount of an air passing through between heat transfer materials can be sufficiently cooled, and provide a manufacturing method of the electric part.SOLUTION: An electric part comprises: a plurality of first heating elements 23; a second heating element 24 of which a heat generation amount is smaller than that of the plurality of first heating elements, and that is provided between the plurality of first heating elements in regard to an arrangement direction, and is provided so as to be separated from the plurality of first heating elements in regard to a depth direction; a substrate 21 that includes a front surface 21A to which the plurality of first heating elements and the second heating element are arranged; a radiator plate 32 that is provided onto a front surface side so as to be overlapped with the plurality of first heating elements in regard to a thickness direction; an inclusion member 35 that is individually provided between the plurality of first heating elements and the radiation plate in regard to the thickness direction, and in which a flow channel 36 in which an air for cooling the second heating element in regard to the depth direction can flow is formed; and a positioning part 37 that determines a position of an end part of a direction orthogonal to the thickness direction in the inclusion member.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The disclosure described in this specification relates to electrical components and a method for manufacturing electrical components.

Background Art

[0002] Patent Document 1 describes a configuration in which a plurality of heating elements are mounted on a circuit board, and the plurality of heating elements are in contact with a heat radiating member via a heat transfer material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In addition to a plurality of heating elements, another electrical element is provided on the circuit board. The electrical element is provided between the plurality of heating elements at a position on the circuit board that does not overlap with the heat radiating member and is away from the plurality of heating elements in the depth direction orthogonal to the arrangement direction. In the configuration of Patent Document 1, the position of the end of the heat transfer material cannot be controlled, and it is difficult to sufficiently cool the electrical element by the wind passing between the heat transfer materials. <00000s27> Therefore, an object of the present disclosure is to provide an electrical component capable of sufficiently cooling a second heating element by wind passing through a flow path, and a method for manufacturing the electrical component.

Means for Solving the Problems

[0006] An electrical component according to an aspect of the present disclosure is a plurality of first heating elements (23), a second heating element (24) having a smaller heat generation amount than the plurality of first heating elements, provided between the plurality of first heating elements with respect to the arrangement direction in which the plurality of first heating elements are arranged, and away from the plurality of first heating elements with respect to the depth direction orthogonal to the arrangement direction. A substrate (21) having a surface (21A) on which multiple first heating elements and second heating elements are provided, A heat sink (32) is provided on the surface side so as to overlap with multiple first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between multiple first heating elements and a heat sink in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, The intervening member comprises a positioning section (37) that determines the position of the end portion in a direction perpendicular to the thickness direction, 、 As a positioning part, the heat sink is provided with a groove (37A) that is recessed in the thickness direction so as to move away from the substrate. The intervening member is inserted into the groove. ru. An electrical component according to another aspect of this disclosure is: Multiple first heating elements (23) and A second heating element (24) is provided which generates less heat than the multiple first heating elements, is located between the multiple first heating elements in the direction in which the multiple first heating elements are arranged, and is also located away from the multiple first heating elements in the depth direction perpendicular to the direction in which they are arranged, A substrate (21) having a surface (21A) on which multiple first heating elements and second heating elements are provided, A heat sink (32) is provided on the surface side so as to overlap with multiple first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between multiple first heating elements and a heat sink in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, It includes a positioning section (37) that determines the position of the end portion of the intervening member in a direction perpendicular to the thickness direction, As a positioning element, a through-hole (37C) is provided in the substrate that penetrates in the thickness direction. An intervening component is inserted into the through-hole. An electrical component according to another aspect of this disclosure is: Multiple first heating elements (23) and A second heating element (24) is provided which generates less heat than the multiple first heating elements, is located between the multiple first heating elements in the direction in which the multiple first heating elements are arranged, and is also located away from the multiple first heating elements in the depth direction perpendicular to the direction in which they are arranged, A substrate (21) having a surface (21A) on which multiple first heating elements and second heating elements are provided, A heat sink (32) is provided on the surface side so as to overlap with multiple first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between multiple first heating elements and a heat sink in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, It includes a positioning section (37) that determines the position of the end portion of the intervening member in a direction perpendicular to the thickness direction, The width of the arrangement on the side of the distribution path that is further away from the second heating element in the depth direction is wider than the width of the arrangement on the side of the second heating element in the depth direction.

[0007] Because the position of the end of the intervening member (35) can be controlled to a desired position, the second heating element (24) can be sufficiently cooled by the air passing through the flow path (36).

[0008] Furthermore, a method for manufacturing an electrical component according to one aspect of this disclosure is: A plurality of first heating elements (23), and a second heating element (24) which has a smaller calorific value than the plurality of first heating elements and is provided between the plurality of first heating elements in the arrangement direction in which the plurality of first heating elements are arranged and away from the plurality of first heating elements in the depth direction orthogonal to the arrangement direction. With respect to the substrate (21) provided on the surface (21A), a heat sink (32) in which intervening members (35) are individually provided at locations facing the first heating elements in the thickness direction of the substrate is provided on the surface side. Approach the substrate and the heat sink in the thickness direction to crush the intervening members. The positioning portion (37) determines the positions of the ends of the intervening members in the direction orthogonal to the thickness direction, and forms a flow path (36) through which air for cooling the second heating element can flow between the intervening members arranged in the arrangement direction with respect to the depth direction. death, The positioning part is a jig (39) having a plurality of wall portions (38) spaced apart in the alignment direction, A jig is provided on the side of the substrate in the heat sink. Between two adjacent wall sections in the direction of alignment, intervening members are individually provided at locations facing the first heating element in the thickness direction. Bring the substrate and heat sink closer together in the thickness direction, and crush the intervening material. After determining the position of the end section using the wall section, remove the jig.

[0009] In order to control the positions of the ends of the intervening members (35) to desired positions, the second heating element (24) can be sufficiently cooled by the air passing through the flow path (36).

[0010] Note that the reference numerals in the parentheses above only indicate the correspondence with the configurations described in the embodiments below, and do not limit the technical scope in any way.

Brief Description of the Drawings

[0011] [Figure 1] It is a cross-sectional view showing a schematic configuration of the device. [Figure 2] It is a plan view of the electrical components as viewed from the first surface side. [Figure 3] It is a cross-sectional view taken along line III-III shown in FIG. 2. [Figure 4] It is a plan view of the heat sink as viewed from the facing surface side. [Figure 5] It is a schematic diagram showing the manufacturing method of the first embodiment. [Figure 6] This is a plan view of the heat sink in the second embodiment, as seen from the opposing side. [Figure 7] This is a cross-sectional view of the third embodiment. [Figure 8] This is a schematic diagram showing the manufacturing method of the third embodiment. [Figure 9] This is a cross-sectional view of the fourth embodiment. [Figure 10] This is a plan view of the substrate in the fourth embodiment. [Figure 11] This is a plan view of the substrate in the fourth embodiment. [Figure 12] This is a schematic diagram showing the manufacturing method of the fourth embodiment. [Figure 13] This is a plan view of the fifth embodiment. [Figure 14] This is a plan view of the sixth embodiment. [Figure 15] This is a cross-sectional view comparing the widths of the inflow passages. [Figure 16] This is a plan view of the seventh embodiment. [Figure 17] This is a plan view of the eighth embodiment. [Figure 18] This is a plan view of the ninth embodiment. [Figure 19] This is a schematic diagram showing the manufacturing method of the 10th embodiment. [Figure 20] This is a schematic diagram showing the manufacturing method of the 10th embodiment. [Figure 21] This is a schematic diagram showing the manufacturing method of the 10th embodiment. [Figure 22] This is a schematic diagram showing the manufacturing method of the 10th embodiment. [Modes for carrying out the invention]

[0012] The following describes several embodiments for implementing this disclosure with reference to the drawings. In each embodiment, parts corresponding to matters described in a preceding embodiment may be denoted by the same reference numerals, and redundant explanations may be omitted. If only a part of the configuration is described in each embodiment, other embodiments described in a preceding embodiment may be applied to the remaining parts of the configuration.

[0013] Furthermore, not only are combinations of parts explicitly shown as being combinable in each embodiment possible, but it is also possible to partially combine embodiments even if not explicitly shown, as long as there are no particular problems with the combination.

[0014] (First Embodiment) In Figure 1, the device 1 comprises a rotating electric machine 2, an electrical circuit 7, a heat sink 31, and an intervening member 35. The rotating electric machine 2 comprises a shaft 3, a stator 4, a rotor 5, and a housing 9. The electrical circuit 7 includes circuit elements that control the supply of power to the stator 4 or rotor 5. An intervening member 35 is provided between the electrical circuit 7 and the heat sink 31 to improve the heat dissipation of the circuit elements. The housing 9 houses some of the components that make up the rotating electric machine 2, as well as the electrical circuit 7, the heat sink 31, and the intervening member 35. The electrical circuit 7, the heat sink 31, and the intervening member 35 are sometimes collectively referred to as electrical components 20.

[0015] The rotating electric machine 2 also includes a machine room 6 that houses the stator 4 and the rotor 5. The rotating electric machine 2 further includes a circuit room 8 that houses the electrical circuit 7. Part of the shaft 3 and electrical components 20 are provided in the circuit room 8. The machine room 6 and the circuit room 8 are separated by a housing 9. The housing 9 is fixed. The rotating electric machine 2 includes bearings 10 and 11 that rotatably support the shaft 3 relative to the housing 9.

[0016] Equipment 1 is called a mechatronic integrated device, comprising a rotating electric machine 2 and an electrical circuit 7. Equipment 1 provides a variety of devices, such as ventilation fans, vacuum cleaners, water pumps, and electric bicycles. A typical example of Equipment 1 is equipment for vehicles. Equipment 1 provides, for example, a heat pump motor, an electric blower, an electric compressor, and a rotating electric machine for propulsion. Equipment 1 is suitable for use in devices in which the shaft 3 rotates continuously.

[0017] The rotating electric machine 2 can function as at least an electric motor. Alternatively, the rotating electric machine 2 may function as a generator. Furthermore, alternatively, the rotating electric machine 2 may function as a motor-generator. The rotating electric machine 2 can be provided by a commutator-type rotating electric machine equipped with a commutator such as brushes, or by a brushless rotating electric machine. In this embodiment, the rotating electric machine 2 is provided by a brushless motor.

[0018] In this embodiment, device 1 provides a blower. The blower blows conditioned air in an air conditioning system. The air conditioning system supplies temperature-controlled air to a target space. The air conditioning system includes, for example, air conditioning systems for buildings such as residences and offices that have rooms where people stay. The air conditioning system also includes air conditioning systems for vehicles that have crew compartments where people ride. Vehicles include cars, ships, aircraft, amusement equipment, simulation equipment, etc. The air conditioning system includes a heat exchanger that exchanges heat with the airflow generated by the blower. The air conditioning system adjusts the temperature of the air by cooling and / or heating the air using the heat exchanger.

[0019] In addition to the components described above, device 1 includes a fan 12, which is a driven component acting as a blower. The fan 12 is provided as either an axial fan or a centrifugal fan. The fan 12 is connected to the shaft 3 by a boss. As a result, the shaft 3 and the fan 12 rotate together. The fan 12 is made of resin. Alternatively, the fan 12 may be made of a metal such as aluminum.

[0020] The stator 4 comprises a stator core 13 fixed to the housing 9. The stator 4 also comprises a stator coil 14 mounted on the stator core 13. The stator coil 14 is wound on an electrically insulating bobbin. The stator core 13 and the stator coil 14 provide a plurality of stator poles. In this embodiment, the salient pole type stator core 13 forms a plurality of stator poles on its outer circumferential surface.

[0021] The rotor 5 includes a rotor yoke 15 connected to the shaft 3. The rotor 5 includes a magnet 16 fixed to the rotor yoke 15. The rotor yoke 15 and the magnet 16 provide multiple rotor poles. The rotor yoke 15 is positioned such that the stator poles and rotor poles face each other. In this embodiment, the cup-shaped rotor yoke 15 is connected to the shaft 3 at its bottom and supports the magnet 16 on the inner wall surface of its outer circumference. As a result, the rotor yoke 15 and the magnet 16 form multiple rotor poles on the inner wall surface. In this embodiment, the magnet 16 is positioned so as to face the stator core 13 in the radial direction.

[0022] Housing 9 includes a center housing 17, an inner housing 18, and an outer housing 19. The center housing 17 partitions the machine room 6 and the circuit room 8 by separating them. The inner housing 18 is also called the second housing or rotating electric machine cover. The inner housing 18 is connected to the center housing 17. Together with the center housing 17, the inner housing 18 is positioned to partition the machine room 6. The inner housing 18 has a cup-shaped form.

[0023] The outer housing 19 is also called the third housing or circuit cover. The outer housing 19 is partially connected to the center housing 17. Together with the center housing 17, the outer housing 19 is positioned to partition the circuit chamber 8. The outer housing 19 has a cup-shaped form.

[0024] An extension portion 19A is formed in the outer housing 19, extending radially outward from the rotating electric machine 2. This extension portion 19A is duct-shaped. An air intake port 19B is formed at the tip of the extension portion 19A. This air intake port 19B is formed to communicate with the rotating electric machine holder 50 and opens toward one axial side of the rotating electric machine 2. In addition, an air intake channel 19C is formed inside the extension portion 19A. This air intake channel 19C extends from the air intake port 19B toward the electrical circuit 7.

[0025] The electrical circuit 7 has a thin, flat, plate-like shape in the thickness direction. The shaft 3 passes through the electrical circuit 7. The electrical circuit 7 is positioned perpendicular to the rotation axis AX of the shaft 3. The electrical circuit 7 is positioned to spread parallel to the center housing 17. In other words, the electrical circuit 7 can be said to spread along the width direction and depth direction, which are perpendicular to the thickness direction. The thickness direction is sometimes referred to as the TD direction. The width direction is sometimes referred to as the WD direction. The depth direction is sometimes referred to as the DP direction. The width direction corresponds to the direction in which the first heating elements 23, described later, are arranged. The arrangement direction is sometimes referred to as the WD direction. Furthermore, the direction along the plane perpendicular to the thickness direction is sometimes referred to as the plane direction. The direction in which the planes along the WD direction and the DP direction spread is sometimes referred to as the plane direction.

[0026] The electrical circuit 7 is supported within the circuit chamber 8. The electrical circuit 7 is supported by the center housing 17, or the outer housing 19, or both. The electrical circuit 7 includes a plurality of circuit elements. Circuit elements are also called circuit components. The electrical circuit 7 is provided by a printed circuit board or a flexible circuit board. In this embodiment, the printed circuit board or flexible circuit board may be simply referred to as the board 21.

[0027] Multiple circuit elements include active elements such as MOSFETs and passive elements such as capacitors and resistors. The heat generated by the active elements is higher than that generated by the passive elements. In this embodiment, the active elements may be referred to as the first heat-generating elements 23. The passive elements may be referred to as the second heat-generating elements 24. The heat generated by the first heat-generating elements 23 is higher than that generated by the second heat-generating elements 24. In other words, the heat generated by the second heat-generating elements 24 is lower than that generated by the first heat-generating elements 23.

[0028] Furthermore, the multiple circuit elements include through-hole components with lead wires and / or surface-mount components. The multiple circuit elements include wires 25 through which current flows to the stator 4 or rotor 5. The wires 25 are provided by insulated wires or busbars. In addition, the multiple circuit elements include connecting members that connect the circuits. An example of a connecting member is solder. The solder connects the lands of the electrical circuit 7 to the elements.

[0029] As described above, the electrical circuit 7 is located in the circuit chamber 8. The electrical circuit 7 is located away from the center housing 17 in the thickness direction. The substrate 21 has a first surface 21A and a second surface 21B on its reverse side, separated in the TD direction. The first surface 21A faces the center housing 17 in the TD direction. The second surface 21B faces the outer housing 19 in the TD direction. The first surface 21A mainly contains the first heating element 23, the second heating element 24, the intervening member 35, and the connecting member. Other circuit elements are provided on the second surface 21B.

[0030] The heat sink 31 is made of a metal with high thermal conductivity, such as aluminum. The heat sink 31 has a heat sink plate 32 positioned opposite the first surface 21A in the TD direction, and an inclined portion 33 extending from the heat sink plate 32 toward the air intake 19B. The heat sink plate 32 has a flat shape with a thin thickness in the TD direction. The heat sink plate 32 is along the first surface 21A and extends toward the air intake 19B side, straddling the outer end 22B on the air intake 19B side of the substrate 21. The inclined portion 33 extends toward the air intake 19B side from the outer end 32B on the air intake 19B side of the heat sink plate 32 toward the air intake 19B side, away from the center housing 17 in the TD direction.

[0031] The inclined portion 33 is positioned to fill the gap between the substrate 21 and the outer housing 19 from the side of the air intake 19B. As a result, as indicated by arrow A, air flows into the air intake channel 19C through the air intake 19B, and the air that flows into the air intake channel 19C flows toward the heat sink 31. The air that flows toward the heat sink 31 then flows toward the heat sink 32 along the inclined portion 33, and also flows around the inclined portion 33 and between the substrate 21 and the heat sink 32. The air that flows toward the heat sink 32 along the inclined portion 33 actively cools the heat sink 32. The air that has gone around the inclined portion 33 flows between the substrate 21 and the heat sink 32, along the first surface 21A, toward the inner end 22A side away from the air intake 19B.

[0032] The substrate 21 has an inner end 22A and an outer end 22B that are separated in the DP direction. With respect to the DP direction, the outer end 22B is located closer to the air intake 19B than the inner end 22A. As described above, the first surface 21A is provided with a first heating element 23 and a second heating element 24. Specifically, the first surface 21A is provided with three first heating elements 23 and two second heating elements 24.

[0033] Figure 2 is a plan view of the electrical component 20 as seen from the first surface 21A side. The three first heating elements 23 are provided in the region on the outer end 22B side of the first surface 21A. The two second heating elements 24 are provided in the region on the inner end 22A side of the first surface 21A, relative to the three first heating elements 23. With respect to the DP direction, the three first heating elements 23 are provided at a distance from the two second heating elements 24. With respect to the TD direction, a heat sink 32 is provided facing the first surface 21A.

[0034] With respect to the TD direction, the heat sink 32 is positioned to face the three first heat-generating elements 23. With respect to the TD direction, the three first heat-generating elements 23 are positioned between the heat sink 32 and the substrate 21 via an intervening member 35. With respect to the TD direction, the three first heat-generating elements 23 overlap the heat sink 32. With respect to the TD direction, the three first heat-generating elements 23 overlap the substrate 21. The intervening member 35 will be explained in detail later.

[0035] On the other hand, with respect to the TD direction, the two second heating elements 24 do not overlap with the heat sink 32. The heat sink 32 has an inner end 32A and an outer end 32B that are separated in the DP direction. With respect to the DP direction, the outer end 32B is located closer to the air intake 19B than the inner end 32A. An inclined portion 33 is provided on the outer end 32B. With respect to the DP direction, the inner end 32A is located between the inner end 22A and the outer end 22B on the substrate 21.

[0036] <Intervening member> As described above, the electrical circuit 7 includes a first heat-generating element 23, such as a MOSFET, which generates a large amount of heat. The first heat-generating element 23 generates a large amount of heat, and it is necessary to actively dissipate the heat to the outside in order to secure the desired output. For this purpose, a heat sink 32 is provided on the substrate 21 so as to face the first heat-generating element 23. Furthermore, in order to efficiently dissipate the heat generated by the first heat-generating element 23, the first heat-generating element 23 is thermally connected to the heat sink 32 via an intervening member 35.

[0037] In this case, if a flexible intervening member 35 is used, the heat sink 32 and the first heating element 23, and the heat sink 32 and the substrate 21 can be reliably brought into close contact via the intervening member 35. In other words, heat dissipation can be improved. As shown in Figures 2 and 3, the intervening member 35 is provided between the heat sink 32 and the first heating element 23, and between the heat sink 32 and the substrate 21, corresponding to the first heating element 23.

[0038] As an example, the intervening member 35 is a heat-dissipating gel in which a metal oxide or the like is added to silicone. The intervening member 35 has improved thermal conductivity. For example, the intervening member 35 is a fluid gel at room temperature, and hardens to the extent that it is no longer fluid due to the heat generated by the first heating element 23.

[0039] As shown in Figure 4, an elliptical groove 37A is formed on the opposing surface 32C of the heat sink 32 that faces the first heat-generating element 23 in the TD direction, enclosing the first heat-generating element 23 in an annular shape in the planar direction. The groove 37A is recessed from the opposing surface 32C in the TD direction. It can also be said that the groove 37A is recessed away from the substrate 21 in the TD direction. The elliptical groove 37A is formed in the heat sink 32 such that its longitudinal direction is in the DP direction and its short direction is in the WD direction. The heat sink 32 is provided with three individual grooves 37A, each enclosing one of the three first heat-generating elements 23 in the planar direction. The three grooves 37A are provided in the heat sink 32 as means of suppressing the movement of the intervening member 35. Since the three grooves 37A are provided in the heat sink 32 as means of suppressing the movement of the intervening member 35, the grooves 37A are sometimes referred to as positioning portions 37 that determine the position of the end of the intervening member 35.

[0040] The intervening member 35 provides an anchoring effect by fitting into the groove 37A. By fitting the intervening member 35 into the groove 37A, its expansion in the planar direction is suppressed. This determines the position of the end of the intervening member 35 in the planar direction. The intervening member 35 is prevented from protruding from the inside of the ellipse to the outside. It can also be said that the intervening member 35 is contained within the ellipse. Consequently, the intervening member 35 also has an elliptical shape in plan view, with its longitudinal direction in the DP direction and its short direction in the WD direction. Adjacent intervening members 35 in the WD direction are discontinuous.

[0041] <Arrangement of the first and second heating elements> As described above, the heat sink 32 is provided with three individual grooves 37A that surround each of the three first heat-generating elements 23 in the planar direction. Of the three individually provided grooves 37A, two adjacent grooves in the WD direction are spaced a predetermined width L1 apart. Accordingly, of the three intervening members 35 housed inside the grooves 37A, two adjacent members in the WD direction are spaced a predetermined width L1 apart.

[0042] The intervening members 35 are individually provided in relation to the first heating element 23. Two adjacent intervening members 35 in the WD direction are also provided with a gap having a predetermined width L1 between them. The air that flows in after circling around the inclined section 33, as described earlier, flows into these gaps. For this reason, these gaps are sometimes referred to as the airflow path 36.

[0043] As described above, each intervening member 35 has an elliptical shape. Therefore, the width L1 of the flow path 36 is non-uniform with respect to the DP direction. With respect to the DP direction, the width L1 of the flow path 36 gradually narrows from the outer end 32B toward the center of the ellipse. The width L1 of the flow path 36 is narrowest at the position corresponding to the center of the ellipse with respect to the DP direction. With respect to the DP direction, the width L1 of the flow path 36 gradually widens from the center of the ellipse toward the inner end 32A.

[0044] The two second heating elements 24 are each provided between adjacent first heating elements 23 in the WD direction. The two second heating elements 24 are each provided between adjacent intervening members 35 in the WD direction. The two second heating elements 24 are provided a predetermined width L2 apart. The two second heating elements 24 overlap with the flow path 36 in the DP direction. The two second heating elements 24 do not overlap with each of the three first heating elements 23 in the DP direction. Each of the two second heating elements 24 is actively cooled by the air flowing through the flow path 36. Note that the predetermined width L2 may be different from or equal to the predetermined width L1.

[0045] The width of the inflow side in the WD direction of the flow path 36 is wider than the width of the second heating element 24 in the WD direction. In this embodiment, the second heating element 24 is provided within the projection area of ​​the flow path 36 with respect to the DP direction. However, the arrangement of the flow path 36 and the second heating element 24 with respect to the DP direction is not limited to this. The second heating element 24 does not have to be provided within the projection area of ​​the flow path 36 with respect to the DP direction. It is sufficient that the second heating element 24 can be cooled by the air passing through the flow path 36.

[0046] <Manufacturing methods for electrical components> Next, the manufacturing method of the electrical component 20 will be described. First, three first heating elements 23 are placed on the first surface 21A of the substrate 21, spaced apart in the WD direction. Next, two second heating elements 24 are placed spaced apart so that each is between two adjacent first heating elements 23 in the WD direction. Next, a heat sink 32 is prepared, which has three grooves 37A that can individually surround each of the three first heating elements 23 in the planar direction. Next, an intervening member 35 is applied to each of the regions surrounded by the grooves 37A on the heat sink 32. Then, as shown in Figure 5, the substrate 21 and the heat sink 32 are brought close together with each of the three first heating elements 23 and the intervening member 35 facing each other in the TD direction.

[0047] As the substrate 21 and the heat sink 32 approach each other, the intervening member 35 comes into contact with the first heating element 23 and the substrate 21 and expands in the planar direction. Consequently, the expanded end of the intervening member 35 in the planar direction enters the groove 37A. The expansion of the intervening member 35 in the planar direction is suppressed by the groove 37A. This allows the position of the end of the intervening member 35 to be determined to a desired position. The position of the end in the planar direction of the intervening member 35 that is compressed between the substrate 21 and the heat sink 32 can be determined. At the same time, the width of the flow path 36 between adjacent intervening members 35 in the WD direction can be determined to a desired width. Narrowing of the width of the flow path 36 is suppressed. The width of the flow path 36 can be controlled to an extent that the second heating element 24 can maintain the required output performance.

[0048] <Effects and Effects> As described above, a plurality of first heating elements 23 and second heating elements 24 are provided on the first surface 21A. The second heating elements 24 are provided between the plurality of first heating elements 23 in the WD direction. The plurality of first heating elements 23 and second heating elements 24 are separated in the DP direction. In addition, a heat sink 32 is provided so as to face the first surface 21A in the TD direction. In the TD direction, the heat sink 32 is provided on the substrate 21 so as to face the plurality of first heating elements 23.

[0049] With respect to the TD direction, intervening members 35 are individually provided between multiple first heating elements 23 and the heat sink 32. The heat sink 32 is individually provided with a positioning unit 37 that determines the position of the end of the intervening member 35 in the planar direction. The end of the intervening member 35 is determined by the positioning unit 37.

[0050] According to this, the end of the intervening member 35 can be determined to a desired position. Accordingly, the width of the gap between adjacent intervening members 35 can be determined to a desired width. The amount of air passing through the airflow path 36 between the intervening members 35 can be controlled to an extent that allows the second heating element 24 to maintain the required output performance. Because the position of the end of the intervening member 35 can be controlled to a desired position, the second heating element 24 can be sufficiently cooled by the air passing through the airflow path 36. The first heating element 23 can be efficiently cooled by passing through the intervening member 35, and the cooling efficiency of the second heating element 24 can be efficiently improved by ensuring the width of the airflow path 36. This makes it possible to efficiently cool both the first heating element 23 and the second heating element 24.

[0051] As explained above, the air flowing into the air intake channel 19C flows along the inclined section 33 toward the heat sink 32, and also flows around the inclined section 33 between the substrate 21 and the heat sink 32. The air flowing along the inclined section 33 toward the heat sink 32 actively cools the first heat-generating element 23 via the intervening member 35 to the heat sink 32. The air that flows around the inclined section 33 directly cools the second heat-generating element 24. Since the position of the end of the intervening member 35 can be controlled by the positioning unit 37, the amount of air passing between the intervening member 35 can be controlled to an extent that allows the second heat-generating element 24 to maintain the desired output performance. The air flowing into the air intake channel 19C makes it possible to efficiently cool both the first heat-generating element 23 and the second heat-generating element 24.

[0052] As explained above, three first heating elements 23 and two second heating elements 24 are provided on the first surface 21A. With respect to the WD direction, the three first heating elements 23 are arranged via a flow path 36 having a predetermined width L1. With respect to the DP direction, the two second heating elements 24 are provided between two adjacent first heating elements 23 so as to overlap the flow path 36. Since the widths of the two flow paths 36 are each a predetermined width L1, the amount of air flowing through the flow paths 36 is almost equal. As a result, differences in the cooling efficiency of the two second heating elements 24 can be suppressed. If the two second heating elements 24 are of the same type of electronic element, differences in the output performance of the two second heating elements 24 can be suppressed.

[0053] As explained above, the positioning portion 37 is provided in an annular shape so as to surround the first heating element 23 in the planar direction. This prevents the end of the intervening member 35 from protruding from the positioning portion 37. This prevents the width of the flow path 36 in the WD direction from narrowing due to the end of the intervening member 35 protruding from the positioning portion 37.

[0054] Furthermore, each intervening member 35 has an elliptical shape. As a result, with respect to the DP direction, the width L1 of the flow path 36 gradually widens from the center of the ellipse toward the inner end 32A. This makes it possible to overlap one flow path 36 with multiple second heating elements 24 with respect to the DP direction. The multiple second heating elements 24 may be the same type of electronic element or different types of electronic elements. They may also be electronic elements with different heat generation amounts.

[0055] As explained above, a groove 37A is formed in the heat sink 32 as a positioning portion 37. The position of the end of the intervening member 35 is determined by the intervening member 35 fitting into the groove 37A. This makes it easy to install the positioning portion 37 on the heat sink 32.

[0056] (Second Embodiment) In the second embodiment, as shown in Figure 6, the groove 37A forms a discontinuous ellipse in the planar direction. It can also be said that the groove 37A forms a dotted line ellipse in the planar direction. This also makes it possible to determine the position of the end of the intervening member 35. It is desirable that the circumferential length of the discontinuous portion on the circumference of the ellipse is shorter than the circumferential length of the continuous portion on the circumference of the ellipse. This suppresses the end of the intervening member 35 from unintentionally spreading in the planar direction. Furthermore, it is possible to improve the output performance of the second heating element 24 because the margin required to account for the width of the flow path 36 during design can be reduced.

[0057] (Third embodiment) In the third embodiment, as shown in Figures 7 and 8, a protrusion 37B is provided on the heat sink 32 as a positioning portion 37, projecting in the TD direction toward the substrate 21. The protrusion 37B can also be said to protrude in the TD direction from the opposing surface 32C. In plan view, the protrusion 37B has an elliptical shape that surrounds the first heating element 23 in an annular shape. The elliptical shape may be continuous or discontinuous. The protrusion 37B acts as a wall that prevents the intervening member 35 from spreading in the planar direction. The intervening member 35 is in contact with the inner surface of the protrusion 37B. As a result, the protrusion 37B prevents the intervening member 35 from spreading in the planar direction.

[0058] The position of the end of the intervening member 35 may be determined in this manner. Note that the shape of the protrusion 37B in plan view is not limited to an elliptical shape. The shape of the protrusion 37B in plan view may be circular, square, or triangular.

[0059] (Fourth Embodiment) In the fourth embodiment, as shown in Figures 9 to 12, a plurality of through-holes 37C are provided in the substrate 21 as a positioning portion 37, which penetrate in the TD direction. In a plan view, the through-holes 37C are provided in a plurality so as to surround the first heating element 23 in an annular shape. As shown in Figure 9, an intervening member 35 is inserted into each of the plurality of through-holes 37C. This determines the position of the end of the intervening member 35 in the planar direction. Also, as shown in Figures 10 and 11, the through-holes 37C may or may not be perfectly circular in a plan view.

[0060] As an example, in a plan view, a rectangle may be formed by multiple through-holes 37C surrounding the first heating element 23. Furthermore, the shape formed by the multiple through-holes 37C is not limited to a rectangle. A circle, ellipse, triangle, etc., may be formed by the multiple through-holes 37C.

[0061] As shown in Figure 12, in the manufacturing process of the fourth embodiment, intervening members 35 are individually applied to each portion of the heat sink 32 facing the three first heating elements 23. Then, with each of the three first heating elements 23 and the intervening member 35 facing each other in the TD direction, the substrate 21 and the heat sink 32 are brought close together. As the substrate 21 and the heat sink 32 approach each other, the intervening members 35 come into contact with the first heating elements 23 and the substrate 21 and spread out in the planar direction.

[0062] Consequently, the end portion of the intervening member 35 that extends in the planar direction enters the through-hole 37C. The extension of the intervening member 35 in the planar direction is suppressed by the through-hole 37C. This allows the position of the end portion of the intervening member 35 to be determined to a desired position. The width of the flow path 36 between adjacent intervening members 35 in the WD direction can be determined to a desired width. Narrowing of the width of the flow path 36 is suppressed. The width of the flow path 36 can be controlled to an extent that allows the second heating element 24 to maintain the required output performance.

[0063] (Fifth and sixth embodiments) In the fifth embodiment, as shown in Figure 13, the positioning portion 37 may be trapezoidal in plan view. In the sixth embodiment, as shown in Figure 14, the positioning portion 37 may be triangular in plan view. In the fifth and sixth embodiments, the positioning portion 37 is provided on the heat sink 32 or substrate 21 such that the base widens from the outer end 32B to the inner end 32A. The positioning portion 37 may be a groove 37A, a protrusion 37B, or a through-hole 37C.

[0064] The upper part of Figure 15 shows a cross-sectional view along line XV-A as shown in Figures 13 and 14. The lower part of Figure 15 shows a cross-sectional view along line XV-B as shown in Figures 13 and 14. With respect to the DP direction, the width L1 of the flow path 36 on the inner end 22A side is narrower than the width L1 of the flow path 36 on the outer end 22B side with respect to the DP direction. With respect to the DP direction, the width L1 of the flow path 36 on the outer end 22B side is wider than the width L1 of the flow path 36 on the inner end 22A side with respect to the DP direction. As a result, the airflow speed in the flow path 36 increases on the inner end 32A side. Consequently, heat exchange between the second heating element 24 and the airflow becomes easier. This makes it possible to efficiently cool the second heating element 24. The second heating element 24 is provided on the inner end 22A side. The first heating element 23 is provided on the outer end 22B side. It can also be said that the outer end 22B side is farther from the second heating element 24 with respect to the DP direction.

[0065] (Seventh Embodiment) In the seventh embodiment, as shown in Figure 16, the positioning portion 37 may be rectangular in shape in a plan view. In the first to seventh embodiments, the shapes of the three intervening members 35, which are spaced apart in the WD direction, are equal. The three intervening members 35 are provided on the heat sink 32 or substrate 21 at equal intervals with respect to the WD direction. It can also be said that the width L1 of the two flow paths 36, which are aligned in the WD direction, are equal. As a result, the airflow through each of the flow paths 36 is almost equal. This has the effect of suppressing differences in the cooling efficiency of the two second heat-generating elements 24.

[0066] (Eighth embodiment) In the eighth embodiment, the two second heating elements 24 are different. For example, one of the second heating elements 24 may be a capacitor and the other a resistor. The amount of heat generated by a capacitor is greater than that generated by a resistor. Capacitors require more cooling than resistors. For this reason, in the eighth embodiment, as shown in Figure 17, the widths L1 of the two flow paths 36 aligned in the WD direction are made different.

[0067] The respective flow paths 36 and the second heating element 24 overlap with respect to the DP direction. The width L1 of the flow path 36 overlapping with the capacitor is wider than the width L1 of the flow path 36 overlapping with the resistor. In other words, the width L1 of the flow path 36 overlapping with the resistor is narrower than the width L1 of the flow path 36 overlapping with the capacitor. In the eighth embodiment, the width L1 of the two flow paths 36 aligned with respect to the WD direction is controlled in accordance with the amount of heat generated by the second heating element 24.

[0068] (Ninth Embodiment) In the ninth embodiment, as shown in Figure 18, the three positioning units 37 each have different shapes in a plan view. In this case, the widths L1 of the two flow paths 36 are different. Each flow path 36 and the second heating element 24 overlap with respect to the DP direction. One of the two flow paths 36, the narrower one, and one of the two second heating elements 24, the one with the smaller heat output, overlap with respect to the DP direction. One of the two flow paths 36, the wider one, and one of the two second heating elements 24, the one with the larger heat output, overlap with respect to the DP direction. In the ninth embodiment, the widths L1 of the two flow paths 36 are controlled to correspond to the heat output of the second heating element 24.

[0069] (Tenth embodiment) In the tenth embodiment, the position of the end of the intervening member 35 may be determined during the manufacturing process based on Figures 19 to 22. During the manufacturing process, as shown in Figure 19, a jig 39 is placed on the heat sink 32, which is provided with a plurality of comb-shaped wall portions 38 arranged in the WD direction. As shown in Figure 20, the intervening member 35 is provided between the wall portions 38 arranged in the WD direction and at a location facing the first heating element 23.

[0070] Then, as shown in Figure 21, the jig 39 and the heat sink 32 with the intervening member 35 are brought closer to the substrate 21. As the heat sink 32 and the substrate 21 are brought closer together, the intervening member 35 expands in the planar direction. The intervening member 35 is provided between the wall portions 38. The intervening member 35 expands up to the wall portions 38. The position of the end of the intervening member 35 is determined by the wall portions 38.

[0071] After the intervening member 35 has solidified, the jig 39 is removed from between the heat sink 32 and the substrate 21, as shown in Figure 22. This may determine the position of the end of the intervening member 35. The wall portion 38 is expandable and contractible in the DP direction. When the wall portion 38 contracts in the DP direction, the wall portion 38 is removed from between the heat sink 32 and the substrate 21.

[0072] This also allows the end of the intervening member 35 to be determined to a desired position. Consequently, the width of the airflow path 36 can be determined to a desired width. The amount of air passing between the intervening members 35 can be controlled to an extent that allows the second heating element 24 to maintain the required output performance. [Explanation of symbols]

[0073] 21 Substrate, 21A Surface, 23 First heating element, 24 Second heating element, 32 Heat sink, 35 Intervening member, 36 Flow path, 37 Positioning part, 37A Groove, 37B Protrusion, 37C Through hole, 38 Wall part, 39 Jig

Claims

1. Multiple first heating elements (23) and A second heating element (24) is provided which generates less heat than the plurality of first heating elements, is provided between the plurality of first heating elements in the direction in which the plurality of first heating elements are arranged, and is provided away from the plurality of first heating elements in the depth direction perpendicular to the direction in which the plurality of first heating elements are arranged, A substrate (21) having a surface (21A) on which a plurality of the first heating elements and the second heating elements are provided, A heat sink (32) is provided on the surface side of the substrate so as to overlap with the plurality of first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between a plurality of first heating elements and the heat sink plate in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, The intervening member comprises a positioning section (37) that determines the position of the end portion in a direction perpendicular to the thickness direction, As the positioning portion, the heat sink is provided with a groove (37A) that is recessed in the thickness direction so as to move away from the substrate. An electrical component in which the intervening member is fitted into the groove.

2. Multiple first heating elements (23) and A second heating element (24) is provided which generates less heat than the plurality of first heating elements, is provided between the plurality of first heating elements in the direction in which the plurality of first heating elements are arranged, and is provided away from the plurality of first heating elements in the depth direction perpendicular to the direction in which the plurality of first heating elements are arranged, A substrate (21) having a surface (21A) on which a plurality of the first heating elements and the second heating elements are provided, A heat sink (32) is provided on the surface side of the substrate so as to overlap with the plurality of first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between a plurality of first heating elements and the heat sink plate in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, The intervening member comprises a positioning section (37) that determines the position of the end portion in a direction perpendicular to the thickness direction, As the positioning portion, the substrate is provided with a through-hole (37C) that penetrates in the thickness direction. An electrical component in which the intervening member is inserted into the through-hole.

3. Multiple first heating elements (23) and A second heating element (24) is provided which generates less heat than the plurality of first heating elements, is provided between the plurality of first heating elements in the direction in which the plurality of first heating elements are arranged, and is provided away from the plurality of first heating elements in the depth direction perpendicular to the direction in which the plurality of first heating elements are arranged, A substrate (21) having a surface (21A) on which a plurality of the first heating elements and the second heating elements are provided, A heat sink (32) is provided on the surface side of the substrate so as to overlap with the plurality of first heating elements in the thickness direction of the substrate, Intervening members (35) are individually provided between a plurality of first heating elements and the heat sink plate in the thickness direction, and form a flow path (36) in the depth direction through which air can flow to cool the second heating element, The intervening member comprises a positioning section (37) that determines the position of the end portion in a direction perpendicular to the thickness direction, An electrical component in which the width in the alignment direction on the side of the distribution path that is further away from the second heating element in the depth direction is wider than the width in the alignment direction on the side of the distribution path that is further away from the second heating element in the depth direction.

4. The first heating element comprises three or more elements, The invention comprises two or more of the aforementioned second heating elements, The first heating element is arranged in the direction described above via the flow path, The electrical component according to any one of claims 1 to 3, wherein the second heating element is provided on the surface such that it overlaps with the flow path in the depth direction.

5. The electrical component according to any one of claims 1 to 3, wherein the positioning portion is provided so as to surround the intervening member in an annular shape.

6. The first heating element comprises three or more elements, The invention comprises two or more of the aforementioned second heating elements, The first heating element is arranged in the direction described above via the flow path, The second heating element is provided on the surface such that it overlaps with the flow path in the depth direction, The electrical component according to any one of claims 1 to 3, wherein the positioning portion is provided so as to surround the intervening member in an annular shape.

7. As the positioning portion, the heat sink is provided with a protrusion (37B) that protrudes in the thickness direction so as to approach the substrate. The electrical component according to any one of claims 1 to 3, wherein the intervening member is in contact with the inner surface of the protrusion.

8. The first heating element comprises three or more elements, The invention comprises two or more of the aforementioned second heating elements, The first heating element is arranged in the direction described above via the flow path, The second heating element is provided on the surface such that it overlaps with the flow path in the depth direction, As the positioning portion, the heat sink is provided with a protrusion (37B) that protrudes in the thickness direction so as to approach the substrate. The electrical component according to any one of claims 1 to 3, wherein the intervening member is in contact with the inner surface of the protrusion.

9. As the positioning portion, the substrate is provided with a through-hole (37C) that penetrates in the thickness direction. The electrical component according to claim 1, wherein the intervening member is inserted into the through-hole.

10. The positioning portion is provided so as to surround the intervening member in an annular shape. The positioning portion is elliptical in shape when viewed from the thickness direction, as described in any one of claims 1 to 3.

11. The first heating element comprises three or more elements, The invention comprises two or more of the aforementioned second heating elements, The first heating element is arranged in the direction described above via the flow path, The second heating element is provided on the surface such that it overlaps with the flow path in the depth direction, The positioning portion is provided so as to surround the intervening member in an annular shape. The positioning portion is elliptical in shape when viewed from the thickness direction, as described in any one of claims 1 to 3.

12. The electrical component according to claim 1 or 2, wherein the width in the alignment direction on the side of the distribution path that is further away from the second heating element in the depth direction is wider than the width in the alignment direction on the side of the distribution path that is further away from the second heating element in the depth direction.

13. A heat sink (32) is provided on the surface (21A) of a substrate (21) on which a plurality of first heating elements (23) and a second heating element (24) which generates less heat than the plurality of first heating elements and is provided between the plurality of first heating elements in the direction in which the plurality of first heating elements are arranged, and away from the plurality of first heating elements in the depth direction perpendicular to the direction in which the plurality of first heating elements are arranged, with intervening members (35) individually provided on the surface side of the substrate (21) on which a heat sink (32) is provided in which intervening members (35) are individually provided in the thickness direction of the substrate and facing the first heating elements. The substrate and the heat sink are brought closer together in the thickness direction, and the intervening member is crushed. The positioning unit (37) determines the position of the end of the intervening member in a direction perpendicular to the thickness direction, and a flow path (36) is formed between the intervening members arranged in the alignment direction, through which air for cooling the second heating element can flow in the depth direction. The positioning portion is a jig (39) having a plurality of wall portions (38) spaced apart in the direction of alignment, The jig is provided on the side of the substrate in the heat sink. Between two adjacent wall portions in the aforementioned alignment direction, the intervening members are individually provided at locations facing the first heating element in the thickness direction. The substrate and the heat sink are brought closer together in the thickness direction, and the intervening member is crushed. A method for manufacturing an electrical component, in which the position of the end portion is determined by the wall portion, and the jig is removed.

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