Electrical component module, refrigeration cycle device, and method for manufacturing electrical component module

Abstract

An electrical component module (100) comprises a first heat-generating component (130a), a substrate (110), a heat sink (140), a first member (120), and a screw (160). The substrate (110) has a mounting surface (111) on which the first heat-generating component (130a) is mounted. The heat sink (140) is thermally connected to the first heat-generating component (130a). The heat sink (140) has a screw hole (143) penetrating in the thickness direction. The first member (120) is disposed between the mounting surface (111) and the heat sink (140) and is fixed to the mounting surface (111). The first member (120) has a screw receiver (123). The screw (160) is inserted into the screw hole (143) from an upper surface (141), which is opposite to a lower surface (142) of the heat sink (140) facing the mounting surface (111), and is fixed to the first member (120).

Description

Electrical equipment module, refrigeration cycle device, and method for manufacturing electrical equipment module

[0001] The present invention relates to an electrical component module, a refrigeration cycle device, and a method for manufacturing an electrical component module.

[0002] Heat-generating components, such as power modules that handle large currents in equipment, generate heat and reach high temperatures during use. To prevent damage from excessive temperature rise, these components are often used in conjunction with heat-dissipating components, such as heat sinks or coolant jackets. The heat generated by the heat-generating component is transferred to a heat-dissipating component in direct or indirect contact with the heat-generating component, and then released into a relatively cooler area, such as the atmosphere or a fluid coolant.

[0003] In order to efficiently cool the heat-generating components, it is necessary to improve the thermal conduction between the heat-generating components and the heat-dissipating components. For example, in Patent Document 1 (WO 2009 / 150804), a power element (heat-generating component) and a heat transfer plate (heat-dissipating component) are fixed by screws passing through the power element side, thereby appropriately connecting the refrigerant jacket and the power element.

[0004] Equipment maintenance often involves removing and replacing heat-generating and heat-dissipating components. However, the electrical component module disclosed in Patent Document 1 has screw heads facing the board when the heat-generating and heat-dissipating components are mounted on the board. This requires that screw holes for maintenance be drilled in the board in advance.

[0005] An electrical equipment module according to a first aspect includes a first heat-generating component, a substrate, a heat sink, a first member, and a screw. The first heat-generating component has a first main body and leads extending from the first main body. The substrate has a mounting surface on which the first heat-generating component is mounted. The heat sink is thermally connected to the first heat-generating component. The heat sink also has a screw hole penetrating through it in the thickness direction. The first member is disposed between the mounting surface and the heat sink and is fixed to the mounting surface. The first member also has a screw receptacle. The screw is inserted into the screw hole from the surface of the heat sink opposite the surface facing the mounting surface, and is fixed to the first member.

[0006] In the electrical component module of the first aspect, there is no need to provide screw holes in the substrate.

[0007] The electrical equipment module of a second aspect is the electrical equipment module of the first aspect, wherein the substrate has a first hole penetrating in a thickness direction, and the first member has a positioning portion for determining the position of the first member relative to the mounting surface, and the positioning portion is inserted into the first hole.

[0008] In the electrical component module of the second aspect, the position of the first member relative to the board can be determined.

[0009] An electrical equipment module according to a third aspect is the electrical equipment module according to the second aspect, wherein the diameter of the first hole is smaller than the diameter of the screw hole of the screw receiver.

[0010] In the electrical equipment module of the third aspect, there is no need to provide a large hole in the substrate.

[0011] An electrical equipment module according to a fourth aspect is the electrical equipment module according to the first or second aspect, wherein the first member further includes a nut as a member constituting the screw receiver.

[0012] In the electrical equipment module of the fourth aspect, the screw can be fixed to the nut.

[0013] An electrical equipment module according to a fifth aspect is the electrical equipment module according to the fourth aspect, wherein the first member further has a recess in a first surface facing the heat sink, in which a nut can be placed.

[0014] In the electrical equipment module of the fifth aspect, the arrangement position of the nut can be stabilized.

[0015] An electrical equipment module according to a sixth aspect is the electrical equipment module according to any one of the first to fifth aspects, further comprising a second heat-generating component mounted on the mounting surface. The second heat-generating component has a second body portion having a different height from the first body portion, and leads extending from the second body portion. The first member includes an eleventh member and a twelfth member having different heights. By supporting the first body portion by the eleventh member and supporting the second body portion by the twelfth member, the surfaces of the first and second heat-generating components mounted on the mounting surface that face the heat sink are aligned.

[0016] In the electrical component module of the sixth aspect, the cooling performance of the heat sink for heat generating components of different sizes can be improved.

[0017] An electrical equipment module according to a seventh aspect is the electrical equipment module according to any one of the first to sixth aspects, wherein the plurality of first members are integrally molded.

[0018] In the electrical component module of the seventh aspect, the arrangement of the plurality of first members is facilitated.

[0019] A refrigeration cycle apparatus according to an eighth aspect includes a refrigerant pipe through which a refrigerant flows, and the electrical component module according to any one of the first to seventh aspects. The refrigerant pipe is in contact with a heat sink.

[0020] In the refrigeration cycle apparatus of the eighth aspect, there is no need to provide screw holes in the substrate of the electrical component module.

[0021] A ninth aspect of the present invention is the refrigeration cycle apparatus of the eighth aspect, wherein the heat sink has a second hole through which the refrigerant pipe passes. The refrigerant pipe is joined to the heat sink while passing through the second hole.

[0022] In the refrigeration cycle apparatus of the ninth aspect, the cooling performance of the heat sink for the electrical component module is improved.

[0023] A tenth aspect of the present invention relates to a method for manufacturing an electrical equipment module, the method comprising: a first step, a second step, a third step, and a fourth step. The first heat-generating component has a first body portion and leads extending from the first body portion. The substrate has a mounting surface on which the first heat-generating component is mounted. The first step is to place a first member having a screw receptacle on the mounting surface. The second step is to mount the first heat-generating component on the mounting surface. The third step is to place a heat sink having a screw hole penetrating in the thickness direction so as to be thermally connected to the first heat-generating component. The fourth step is to insert a screw into the screw hole from the surface of the heat sink opposite the surface facing the mounting surface, and fix the heat sink to the first member.

[0024] In the manufacturing method of the electrical equipment module according to the tenth aspect, there is no need to provide screw holes in the substrate.

[0025] 10 is a schematic diagram of an electrical equipment module in a first embodiment. A cross-sectional view taken along line A-A' in FIG. 1. A cross-sectional view of a first member of the electrical equipment module in FIG. 1. A flowchart showing a method for manufacturing the electrical equipment module in FIG. 1. A diagram for explaining an electrical equipment module of modified example 1F. A diagram for explaining an electrical equipment module of modified example 1G. A schematic diagram of an integrally molded first member of modified example 1H. A diagram for explaining an electrical equipment module of modified example 1J. A schematic configuration diagram of an air conditioning device in a second embodiment. A schematic diagram of an electrical equipment module in a second embodiment. A cross-sectional view taken along line B-B' in FIG. 10. A cross-sectional view taken along line CC' in FIG. 10. A diagram for explaining an electrical equipment module of modified example 2A. A diagram for explaining an electrical equipment module of modified example 2B.

[0026] First Embodiment An electrical component module 100 and a manufacturing method for the electrical component module 100 according to an embodiment of the present disclosure will be described with reference to the drawings. In the following description, for convenience of explanation, terms such as up, down, left, and right may be used to describe directions and positional relationships. The directions indicated by these terms correspond to the directions indicated by arrows in the drawings.

[0027] (1) Overall Configuration of Electrical Component Module Fig. 1 is a schematic diagram of an electrical component module 100, and Fig. 2 is a cross-sectional view taken along line A-A' in Fig. 1. The electrical component module 100 includes a substrate 110, a first member 120 disposed on a mounting surface 111 of the substrate 110, a heat-generating component 130 mounted on the substrate 110, a heat sink 140 attached so as to come into contact with the heat-generating component 130, and screws 160.

[0028] (1-1) Substrate The substrate 110 is an insulating plate-like member with a conductive wiring pattern (not shown) provided on its surface. Multiple electronic components are mounted on the substrate 110, and the wiring pattern and electronic components form an electric circuit. The electronic components include a power module, a capacitor, a reactor, etc.

[0029] The substrate 110 has a mounting surface 111 on which a heat-generating component 130 is mounted. Electronic components that do not generate heat when driven or that generate little heat may be mounted on the mounting surface 111, or on the surface opposite the mounting surface 111. The substrate 110 is also formed with a first hole 112 that penetrates through the substrate in the thickness direction. As shown in FIG. 3 , the diameter DM1 of the first hole 112 is smaller than the diameter DM2 of a screw hole in a screw receiver 123 (described later) and is equal to or smaller than 2 mm. As described later, a positioning portion 124 of the first member 120 is inserted into the first hole 112.

[0030] (1-2) First Member The first member 120 is disposed between the mounting surface 111 of the substrate 110 and the heat sink 140 and is fixed to the mounting surface 111. FIG. 3 is a cross-sectional view of the first member 120 disposed on the substrate 110. When the first member 120 is disposed on the substrate 110, the first member 120 has a screw receptacle 123 with a thread on a first surface 121 opposite to a second surface 122 facing the substrate 110. In this embodiment, the screw receptacle 123 is a screw hole formed in the first surface 121. The first surface 121 is the surface facing the heat sink 140. The height of the first member 120 is preferably 4 mm or more. The depth of the screw receptacle 123 is preferably 2 mm or more. With this configuration, the screw 160 can be fixed to the screw receptacle 123.

[0031] The first member 120 also has a positioning portion 124 on the second surface 122 for determining the position of the first member 120 relative to the mounting surface 111. The positioning portion 124 is a rod-shaped body extending perpendicularly from the second surface 122 and has a fitting portion 125 at its end. The fitting portion 125 may be a claw that fits into the substrate 110 by snap-fitting. The first member 120 is fixed to the substrate 110 by inserting the rod-shaped body of the positioning portion 124 into the first hole 112 and hooking the fitting portion 125 onto the substrate 110. As a result, the position of the first member 120 relative to the substrate 110 is determined. Note that, because the first member 120 is made of an insulating material, it is not necessary to consider the insulation distance.

[0032] (1-3) Heat-generating Components The heat-generating components 130 are electronic components that generate a lot of heat when in operation, such as power modules, driver ICs, power transistors, etc. In order for such electronic components to operate normally, they need to be cooled so that their operating temperature does not exceed (for example, 90°C).

[0033] The heat-generating component 130 mainly includes a main body 134 and a plurality of leads 135. When the main body 134 is mounted on the substrate 110, it is located between the heat sink 140 and the substrate 110. An upper surface 131 of the main body 134 (the surface facing the heat sink 140) is in contact with the heat sink 140 so as to provide an appropriate heat transfer area. This thermally connects the heat-generating component 130 to the heat sink 140.

[0034] A third hole 133 is formed in the main body 134 of the heat-generating component 130 to pass the screw 160 from the upper surface 131 to the lower surface 132 (the surface facing the substrate 110). The third hole 133 is a through-hole that does not have a thread groove.

[0035] (1-4) Heat Sink The heat sink 140 is made of a metal with high thermal conductivity, such as aluminum, and is a generally plate-shaped member that is rectangular when viewed in the thickness direction. The heat sink 140 is a heat exchanger that cools the heat-generating component 130 by radiating heat absorbed from the heat-generating component 130 from the surface of the heat sink 140. The heat sink 140 is arranged so as to be thermally connected to the heat-generating component 130. In this embodiment, the heat sink 140 is arranged so as to be in contact with the upper surface 131 of the main body 134 of the heat-generating component 130.

[0036] The heat sink 140 has a screw hole 143 formed therein, which penetrates the heat sink 140 in the thickness direction from an upper surface 141 to a lower surface 142 (the surface facing the substrate 110) of the heat sink 140. The screw hole 143 is a through-hole that does not have a thread.

[0037] (2) Detailed Configuration of Electrical Component Module and Manufacturing Method FIG. 4 is a flowchart showing a manufacturing method of the electrical component module 100.

[0038] First, the first member 120 is placed on the mounting surface 111 of the substrate 110 (step S1). The first member 120 includes an eleventh member 120a and a twelfth member 120b. As shown in FIG. 2 , the height H1 of the eleventh member 120a is different from the height H2 of the twelfth member 120b. The rod-shaped bodies of the positioning portions 124 of the eleventh member 120a and the twelfth member 120b are inserted into the first holes 112, and the fitting portions 125 are hooked onto the substrate 110, thereby determining the positions of the eleventh member 120a and the twelfth member 120b relative to the mounting surface 111.

[0039] Next, the heat-generating component 130 is arranged so as to be supported by the first member 120 (step S2). One heat-generating component 130 may be supported by one first member 120 or by multiple first members 120. The heat-generating component 130 includes a first heat-generating component 130a and a second heat-generating component 130b. The first heat-generating component 130a has a first body portion 134a and multiple leads 135a extending from the first body portion 134a. The second heat-generating component 130b has a second body portion 134b and multiple leads 135b extending from the second body portion 134b. The leads 135a and 135b are linear or plate-shaped conductive metals. In this embodiment, the first body portion 134a is arranged on the two first surfaces 121a so that the first body portion 134a is supported by the two eleventh members 120a. Also, the second main body portion 134b is disposed on one of the first surfaces 121b so that the second main body portion 134b is supported by one of the twelfth members 120b.

[0040] The height H1 of the eleventh member 120a, when combined with the height H3 of the first main body portion 134a, is configured to be approximately the same as the combined height H2 of the twelfth member 120b and the height H4 of the second main body portion 134b. Furthermore, the height H2 of the twelfth member 120b, when combined with the height H4 of the second main body portion 134b, is configured to be approximately the same as the combined height H1 of the eleventh member 120a and the height H3 of the first main body portion 134a. Therefore, by arranging the first main body portion 134a and the second main body portion 134b as described above, the height positions of the upper surface 131a of the first main body portion 134a (the surface facing the heat sink 140) and the upper surface 131b of the second main body portion 134b (the surface facing the heat sink 140) are aligned.

[0041] Thereafter, the tips of the leads 135a, 135b of the first heat-generating component 130a and the second heat-generating component 130b are connected to the substrate 110 using an electrical connecting material such as solder, thereby mounting the first heat-generating component 130a and the second heat-generating component 130b on the mounting surface 111.

[0042] Next, the heat sink 140 is positioned so as to contact the upper surfaces 131 a, 131 b of the first body portion 134 a and the second body portion 134 b (step S3). As described above, the height positions of the upper surfaces 131 a, 131 b of the first body portion 134 a and the second body portion 134 b facing the heat sink 140 are aligned. Therefore, by positioning the heat sink 140 so that the first body portion 134 a is sandwiched between the heat sink 140 and the first surfaces 121 a of the two eleventh members 120 a and the second body portion 134 b is sandwiched between the heat sink 140 and the first surface 121 b of the one twelfth member 120 b, the heat sink 140 can be positioned so as to contact the upper surfaces 131 a, 131 b of the first body portion 134 a and the second body portion 134 b. In this way, by thermally connecting the first heat-generating component 130a and the second heat-generating component 130b to the heat sink 140, the heat generated by the first heat-generating component 130a and the second heat-generating component 130b can be dissipated via the heat sink 140.

[0043] Next, the screw 160 is inserted into the screw hole 143 from the upper surface 141 of the heat sink 140, and the screw 160 is passed through the screw hole 143 and then the third hole 133. The screw 160 is then inserted into the screw receiver 123 of the first member 120 and screwed into the thread groove. This fixes the screw 160 to the first member 120 (step S4).

[0044] (3) Features (3-1) The electrical equipment module 100 of this embodiment includes a first heat-generating component 130a, a substrate 110, a heat sink 140, a first member 120, and a screw 160. The first heat-generating component 130a has a first main body 134a and leads 135a extending from the first main body 134a. The substrate 110 has a mounting surface 111 on which the first heat-generating component 130a is mounted. The heat sink 140 is thermally connected to the first heat-generating component 130a. The heat sink 140 also has a screw hole 143 that penetrates the heat sink 140 in the thickness direction. The first member 120 is disposed between the mounting surface 111 and the heat sink 140 and is fixed to the mounting surface 111. The first member 120 also has a screw receptacle 123. The screws 160 are inserted into the screw holes 143 from the upper surface 141 opposite the lower surface 142 facing the mounting surface 111 of the heat sink 140 , and are fixed to the first member 120 .

[0045] With this configuration, there is no need to provide screw holes in the substrate 110. As a result, it is easier to route the wiring on the substrate 110. Furthermore, because the screws 160 that pass through the heat sink 140 are fixed to the screw sockets 123 of the first member 120, it is possible to prevent the tips of the screws from coming into contact with the substrate 110.

[0046] (3-2) In the electrical equipment module 100 of this embodiment, the substrate 110 has a first hole 112 penetrating in the thickness direction. The first member 120 has a positioning portion 124 for determining the position of the first member 120 with respect to the mounting surface 111. The positioning portion 124 is inserted into the first hole 112.

[0047] With this configuration, the position of the first member 120 relative to the substrate 110 can be determined.

[0048] (3-3) In the electrical equipment module 100 of this embodiment, the diameter DM1 of the first hole 112 is smaller than the diameter DM2 of the screw hole of the screw receiver 123 .

[0049] With this configuration, there is no need to provide a large hole in the substrate 110 .

[0050] (3-4) The electrical equipment module 100 of this embodiment further includes a second heat-generating component 130b mounted on the mounting surface 111. The second heat-generating component 130b has a second body portion 134b that is different in height from the first body portion 134a, and leads 135b extending from the second body portion 134b. The first member 120 includes an eleventh member 120a and a twelfth member 120b that are different in height. By supporting the first body portion 134a by the eleventh member 120a and supporting the second body portion 134b by the twelfth member 120b, the surfaces (top surfaces 131a, 131b) of the first heat-generating component 130a and the second heat-generating component 130b mounted on the mounting surface 111 that face the heat sink 140 are aligned.

[0051] This configuration can improve the cooling performance of the heat sink 140 for heat generating components 130 of different sizes.

[0052] (4) Modifications (4-1) Modification 1A The order of each process in the flowchart described above and the content of each process can be changed as appropriate without departing from the gist of the present disclosure.

[0053] (4-2) Modification 1B In this embodiment, the positioning portion 124 is a rod-shaped body extending perpendicularly from the second surface 122, and has a fitting portion 125 at its end. However, the positioning portion 124 may also be a lead. The lead of the positioning portion 124 does not have to be fixed. By arranging the heat-generating component 130 so that it is supported by the first member 120, when the heat-generating component 130 is fixed to the substrate 110, the position of the first member 120 relative to the mounting surface 111 is also fixed.

[0054] The leads of the positioning portion 124 may be fixed to the substrate 110 using solder. In this case, the position of the first member 120 relative to the mounting surface 111 is fixed even more firmly.

[0055] In this modification, it is not necessary to provide a large hole in the substrate 110 .

[0056] (4-3) Modification 1C The first member 120 may be surface-mounted such that the second surface 122 is surface-mounted on the mounting surface 111 .

[0057] In this modification, there is no need to provide a hole in the substrate 110 for fixing the first member 120 .

[0058] (4-4) Modification 1D The first member 120 may be made of metal.

[0059] (4-5) Modification 1E The outer casing of the first member 120 may be made of an insulating material, and the thread groove of the screw receiver 123 may be made of metal.

[0060] (4-6) Modification 1F As shown in FIG. 5 , the first member 120 may have a nut 150 as a component constituting the screw receiver 123. The nut 150 may be disposed between the first surface 121 and the main body 134. In this case, a threaded hole need not be formed in the first surface 121. The nut 150 is disposed so that a screw 160 inserted into the threaded hole 143 from the upper surface 141 of the heat sink 140 can be threaded into the nut 150. The screw 160 may be inserted into the threaded hole 143 from the upper surface 141 of the heat sink 140, passed through the threaded hole 143 and the third hole 133 in that order, and then threaded onto the nut 150 for fixation.

[0061] In this modification, the height position of the upper surface 131 of the main body 134 can be adjusted by tightening the nut 150 toward the lower surface 132 of the main body 134 of the heat-generating component 130. As a result, even when mounting a plurality of heat-generating components 130 having main bodies 134 with different heights, there is no need to arrange the first members 120 to match the height of each main body 134, thereby reducing costs.

[0062] (4-7) Modification 1G Fig. 6 is a cross-sectional view of the first member 120. The first member 120 may have a recess 127 in which a nut 150 can be placed on the first surface 121. In this case, a screw hole does not need to be formed on the first surface 121. The nut 150 is placed so that it fits into the recess 127. Furthermore, the nut 150 is placed so that a screw 160 inserted into the screw hole 143 from the upper surface 141 of the heat sink 140 can be threaded into the nut 150.

[0063] When the nut 150 is disposed so as to fit into the recess 127, the position of the upper surface of the nut 150 is substantially the same as the position of the first surface 121. In other words, the height H5 of the recess 127 is substantially the same as the height H6 of the nut 150.

[0064] In this modification, the placement position of the nut 150 can be stabilized. As a result, work efficiency is improved. Furthermore, by using the nut 150, the first member 120 can be standardized. Specifically, by tightening the nut 150 toward the lower surface 132 of the main body 134 of the heat-generating component 130, the height position of the upper surface 131 of the main body 134 can be adjusted. As a result, even when multiple heat-generating components 130 having main bodies 134 of different heights are mounted, there is no need to position the first member 120 to match the height of each main body 134, and the first member 120 can be standardized.

[0065] (4-8) Modification 1H A plurality of first members 120 may be integrally molded. FIG. 7 is a diagram showing an integral member 129 in which six first members 120 of different heights are integrally molded. Note that the number of first members 120 is not limited to this. The integral member 129 may have a plurality of positioning portions 124 for determining the position of the integral member 129 relative to the substrate 110. The position of the positioning portions 124 is not limited to the second surface 122 of the first member 120, but may be anywhere on the surface of the integral member 129 that faces the substrate 110.

[0066] In this modification, since a plurality of first members 120 can be arranged at once, the arrangement of the first members 120 becomes easier.

[0067] (4-9) Modification 1I In modification 1H, a plurality of first members 120 arranged in a straight line are integrally molded, but the first members 120 do not have to be arranged in a straight line.

[0068] (4-10) Modification 1J The first member 120 may include a thirteenth member 120c that does not support the heat-generating component 130. In this case, as shown in Fig. 8, the heat sink 140 may be disposed on the first surface 121c of the thirteenth member 120c so that the heat sink 140 is supported by the first surface 121c. Screws 160 may be inserted into screw holes 143 from the upper surface 141 of the heat sink 140, and the screws 160 that have passed through the screw holes 143 may be inserted into screw receivers 123 of the thirteenth member 120c to fix the heat sink to the thirteenth member 120c.

[0069] In this modification, there is no need to form the third hole 133 in the main body 134 of the heat-generating component 130. In addition, there is no need to form the screw receiver 123 in the first member 120 that supports the heat-generating component 130. As a result, costs can be reduced.

[0070] (4-11) Modification 1K A nut 150 may be disposed between the heat sink 140 and the first surface 121c of the thirteenth member 120c that does not support the heat-generating component 130. In this case, the first surface 121c may further have a recess 127. The nut 150 may be disposed so as to fit into the recess 127.

[0071] (4-12) Modification 1L In this embodiment, a third hole 133 is formed in the main body 134 of the heat-generating component 130 to allow the screw 160 to pass through from the upper surface 131 toward the lower surface 132 (the surface facing the substrate 110). However, instead of the third hole 133, a first groove 136 into which the screw 160 can be fitted may be formed in the main body 134. The first groove 136 is formed from the upper surface 131 toward the lower surface 132 on one or more sides of the outer periphery of the main body 134 when viewed in the thickness direction of the main body 134. The first groove 136 has a cross section that is generally arc-shaped or generally U-shaped, and can allow the screw 160 to be fitted therein. In this case, in step S4 of Figure 4, a screw 160 may be inserted into the screw hole 143 from the upper surface 141 of the heat sink 140, passed through the screw hole 143, and the screw 160 fitted into the first groove portion 136 may be inserted into the screw receptacle 123 of the first member 120 and fixed.

[0072] Second Embodiment An air conditioning apparatus (refrigeration cycle apparatus) 1 including an electrical component module 200 according to one embodiment of the present disclosure will be described with reference to the drawings. In the following description, for the sake of convenience, terms such as up, down, left, and right may be used to describe directions and positional relationships. The directions indicated by these terms correspond to the directions indicated by arrows in the drawings.

[0073] (1) Configuration of the Air Conditioner Figure 9 is a schematic diagram of the air conditioner 1. The air conditioner 1 is a device that cools and heats a space to be air-conditioned by using a vapor compression refrigeration cycle. However, the invention is not limited to this, and the air conditioner 1 may be a device that performs only one of cooling and heating. If the air conditioner 1 performs only one of cooling and heating, the air conditioner 1 does not need to have a four-way switching valve 22, which will be described later.

[0074] The refrigeration cycle device of the present disclosure is not limited to the air conditioner 1, and may be a device that performs a vapor compression refrigeration cycle other than an air conditioner. For example, the refrigeration cycle device of the present disclosure may be a refrigeration cycle device for a refrigerator or freezer used to store food, a hot water supply device, or a floor heating device.

[0075] The air conditioning device 1 includes an outdoor unit 2 and an indoor unit 4. The indoor unit 4 and the outdoor unit 2 are connected via a liquid refrigerant communication pipe 5 and a gas refrigerant communication pipe 6 to form a refrigerant circuit 10 in which a refrigerant circulates. The refrigerant circuit 10 is filled with refrigerant.

[0076] (1-1) Outdoor Unit The outdoor unit 2 is installed outdoors and constitutes part of the refrigerant circuit 10. The outdoor unit 2 mainly has a compressor 21, a four-way switching valve 22, an outdoor heat exchanger 23, an expansion valve 26, a liquid-side shut-off valve 27, a gas-side shut-off valve 28, an outdoor fan 36, an outdoor control unit 37, and a heat sink 240.

[0077] The compressor 21 is a device that compresses the low-pressure refrigerant that it draws in to produce high-pressure refrigerant. The compressor 21 has a compressor motor 21a and a rotary or scroll-type compression element (not shown) that rotates in conjunction with the compressor motor 21a. The compressor 21 has a suction pipe 31 connected to its suction side and a discharge pipe 32 connected to its discharge side. The suction pipe 31 is a refrigerant pipe that connects the suction side of the compressor 21 to the four-way switching valve 22. The discharge pipe 32 is a refrigerant pipe that connects the discharge side of the compressor 21 to the four-way switching valve 22.

[0078] The four-way switching valve 22 is a switching valve for switching the direction of refrigerant flow in the refrigerant circuit 10. The four-way switching valve 22 is connected to a suction pipe 31, a discharge pipe 32, a first gas refrigerant pipe 33, and a second gas refrigerant pipe 34. The first gas refrigerant pipe 33 is a refrigerant pipe that connects the four-way switching valve 22 to the gas side of the outdoor heat exchanger 23. The second gas refrigerant pipe 34 is a refrigerant pipe that connects the four-way switching valve 22 to the gas side shut-off valve 28. During cooling operation, the four-way switching valve 22 switches the flow path so that the discharge pipe 32 is connected to the first gas refrigerant pipe 33 and the suction pipe 31 is connected to the second gas refrigerant pipe 34 (see the solid lines of the four-way switching valve 22 in FIG. 9 ). Furthermore, during heating operation, the four-way switching valve 22 switches the flow path so that the discharge pipe 32 and the second gas refrigerant pipe 34 are connected and the suction pipe 31 and the first gas refrigerant pipe 33 are connected (see the dashed lines of the four-way switching valve 22 in Figure 9).

[0079] One end of the outdoor heat exchanger 23 is connected to the first gas refrigerant pipe 33, and the other end is connected to the liquid refrigerant pipe 35. The liquid refrigerant pipe 35 is a refrigerant pipe that connects the liquid side of the outdoor heat exchanger 23 to the liquid refrigerant communication pipe 5. The outdoor heat exchanger 23 is configured to be able to exchange heat between the refrigerant and the outdoor airflow generated by the outdoor fan 36 during operation. The outdoor heat exchanger 23 functions as a refrigerant condenser or radiator during cooling operation, and as a refrigerant evaporator during heating operation.

[0080] The expansion valve 26 reduces the pressure of the high-pressure refrigerant. The expansion valve 26 is disposed on the liquid refrigerant pipe 35. During cooling operation, the expansion valve 26 reduces the pressure of the high-pressure refrigerant that has condensed or released heat in the outdoor heat exchanger 23 to low-pressure refrigerant. During heating operation, the expansion valve 26 reduces the pressure of the high-pressure refrigerant that has condensed or released heat in the indoor heat exchanger 41 to low-pressure refrigerant.

[0081] The heat sink 240 is a heat exchanger that cools the heat-generating components 130 with the refrigerant circulating through the refrigerant circuit 10. In this embodiment, the heat-generating components 130 are cooled by the liquid refrigerant pipe 35. During cooling operation, the heat sink 240 cools the heat-generating components 130 with the high-pressure refrigerant condensed or dissipated heat in the outdoor heat exchanger 23 (i.e., the refrigerant flowing between the outdoor heat exchanger 23 and the expansion valve 26). During heating operation, the heat sink 240 cools the heat-generating components 130 with the low-pressure refrigerant decompressed by the expansion valve 26 (i.e., the refrigerant flowing between the expansion valve 26 and the outdoor heat exchanger 23).

[0082] The outdoor fan 36 is, for example, a propeller fan. The outdoor fan 36 is connected to the output shaft of an outdoor fan motor 36a and is driven in conjunction with the outdoor fan motor 36a. When driven, the outdoor fan 36 generates an outdoor airflow that flows into the outdoor unit 2, passes through the outdoor heat exchanger 23, and then flows out of the outdoor unit 2.

[0083] The outdoor control unit 37 is a microcomputer composed of a CPU, memory, etc. The outdoor control unit 37 controls the operation of each part in the outdoor unit 2. The outdoor control unit 37 is connected to the indoor control unit 43 via a dedicated line 90, and they send and receive signals to and from each other. When the outdoor control unit 37 receives a predetermined signal from the indoor control unit 43, it performs processing corresponding to the signal. The outdoor control unit 37 is included in the electrical component module 200.

[0084] (1-2) Indoor Unit The indoor unit 4 is, for example, a so-called ceiling-embedded, ceiling-suspended, or wall-mounted indoor unit. The indoor unit 4 constitutes part of the refrigerant circuit 10. The indoor unit 4 mainly has an indoor heat exchanger 41, an indoor fan 42, and an indoor control unit 43.

[0085] One end of the indoor heat exchanger 41 is connected to the liquid refrigerant communication pipe 5, and the other end is connected to the gas refrigerant communication pipe 6. The indoor heat exchanger 41 is configured to be able to exchange heat between the refrigerant and the indoor airflow generated by the indoor fan 42 during operation. The indoor heat exchanger 41 functions as a refrigerant evaporator during cooling operation, and as a refrigerant condenser or radiator during heating operation.

[0086] The indoor fan 42 is, for example, a propeller fan or a multi-blade fan, and is connected to the output shaft of an indoor fan motor 42 a. The indoor fan 42 is driven in conjunction with the indoor fan motor 42 a. When driven, the indoor fan 42 generates an indoor air flow that flows into the indoor unit 4, passes through the indoor heat exchanger 41, and then flows out of the indoor unit 4.

[0087] The indoor control unit 43 is a microcomputer composed of a CPU, memory, etc. The indoor control unit 43 controls the operation of each part in the indoor unit 4. The indoor control unit 43 transmits and receives signals to and from the outdoor control unit 37 or a remote control (not shown), and when it receives a predetermined signal, it performs processing corresponding to the signal.

[0088] (2) Refrigerant Flow in the Refrigerant Circuit (2-1) Refrigerant Flow During Cooling Operation During cooling operation, the four-way selector valve 22 is switched to the cooling cycle state (the state indicated by the solid line in FIG. 9 ). When the compressor 21 is driven in this state, low-pressure gas refrigerant is drawn into the compressor 21 and compressed to become high-pressure gas refrigerant. The high-pressure gas refrigerant discharged from the compressor 21 is sent to the outdoor heat exchanger 23 through the four-way selector valve 22. In the outdoor heat exchanger 23, the high-pressure gas refrigerant exchanges heat with the outdoor airflow generated by the outdoor fan 36, and condenses to become high-pressure liquid refrigerant. The high-pressure liquid refrigerant condensed in the outdoor heat exchanger 23 is sent to the liquid refrigerant piping 35.

[0089] The high-pressure liquid refrigerant sent to the liquid refrigerant pipe 35 exchanges heat with the heat-generating component 130 in the heat sink 240. At this time, the heat-generating component 130 is cooled according to the flow rate (i.e., the refrigerant circulation rate) and temperature of the refrigerant flowing through the liquid refrigerant pipe 35. This prevents the temperature of the heat-generating component 130 from rising above the operating temperature, which is the temperature range in which the heat-generating component 130 can operate normally, during operation. The high-pressure liquid refrigerant that has exchanged heat with the heat-generating component 130 in the heat sink 240 is sent to the expansion valve 26.

[0090] The high-pressure liquid refrigerant sent to the expansion valve 26 is decompressed in the expansion valve 26 to become low-pressure gas-liquid two-phase refrigerant. The low-pressure gas-liquid two-phase refrigerant decompressed in the expansion valve 26 is sent to the indoor heat exchanger 41 through the liquid-side shut-off valve 27 and the liquid refrigerant communication pipe 5.

[0091] The low-pressure gas-liquid two-phase refrigerant sent to the indoor heat exchanger 41 exchanges heat with the indoor air flow generated by the indoor fan 42 in the indoor heat exchanger 41, and evaporates to become low-pressure gas refrigerant. The low-pressure gas refrigerant evaporated in the indoor heat exchanger 41 passes through the gas refrigerant communication pipe 6, the gas-side shut-off valve 28, and the four-way switching valve 22, and is sucked back into the compressor 21.

[0092] (2-2) Refrigerant Flow During Heating Operation During heating operation, the four-way selector valve 22 is switched to the heating cycle state (the state indicated by the dashed line in FIG. 9 ). When the compressor 21 is driven in this state, low-pressure gas refrigerant is drawn into the compressor 21 and compressed to become high-pressure gas refrigerant. The high-pressure gas refrigerant discharged from the compressor 21 is sent to the indoor heat exchanger 41 through the four-way selector valve 22, the gas-side shut-off valve 28, and the gas refrigerant communication pipe 6. In the indoor heat exchanger 41, the high-pressure gas refrigerant exchanges heat with the indoor airflow generated by the indoor fan 42 and condenses into high-pressure liquid refrigerant. The high-pressure liquid refrigerant condensed in the indoor heat exchanger 41 is sent to the expansion valve 26 through the liquid refrigerant communication pipe 5 and the liquid-side shut-off valve 27. The high-pressure liquid refrigerant sent to the expansion valve 26 is decompressed in the expansion valve 26 to become low-pressure refrigerant in a gas-liquid two-phase state. The low-pressure refrigerant in a gas-liquid two-phase state, which has been decompressed by the expansion valve 26, is sent to the liquid refrigerant pipe 35.

[0093] The low-pressure refrigerant in a gas-liquid two-phase state sent to the liquid refrigerant pipe 35 exchanges heat with the heat-generating component 130 in the heat sink 240. At this time, the heat-generating component 130 is cooled according to the flow rate (i.e., the refrigerant circulation rate) and temperature of the refrigerant flowing through the liquid refrigerant pipe 35. This prevents the temperature of the heat-generating component 130 from rising above an operating temperature, which is a temperature range in which the heat-generating component 130 can operate normally, during operation. The gas-liquid two-phase refrigerant that has exchanged heat with the heat-generating component 130 in the heat sink 240 is sent to the outdoor heat exchanger 23.

[0094] The low-pressure gas-liquid two-phase refrigerant sent to the outdoor heat exchanger 23 exchanges heat with the outdoor air flow generated by the outdoor fan 36 in the outdoor heat exchanger 23, and evaporates to become low-pressure gas refrigerant. The low-pressure gas refrigerant evaporated in the outdoor heat exchanger 23 is sucked back into the compressor 21 through the four-way selector valve 22.

[0095] (3) Detailed Configuration of Electrical Component Module FIG. 10 is a schematic diagram of the electrical component module 200, and FIG. 11 is a cross-sectional view taken along line B-B' in FIG. 10. FIG. 12 is a cross-sectional view taken along line C-C' in FIG. 10. The electrical component module 200 includes a plurality of electrical and electronic components for controlling the operation of the outdoor unit 2. The electrical component module 200 includes a substrate 110, a first member 120 disposed on a mounting surface 111 of the substrate 110, a heat-generating component 130 mounted on the substrate 110, a heat sink 240 attached so as to come into contact with the heat-generating component 130, and screws 160. The following mainly describes the differences from the electrical component module 100 according to the first embodiment.

[0096] (3-1) Heat-Generating Components The heat-generating components 130 are, for example, an inverter module that controls the operating frequency of the compressor motor 21 a or an inverter module that controls the operating frequency of the outdoor fan motor 36 a. For the air conditioning apparatus 1 to operate normally, the heat-generating components 130 need to be cooled so that they do not exceed an operable temperature (for example, 90°C).

[0097] (3-2) Heat Sink The heat sink 240 mainly includes a heat sink body 240 a and a cover 240 b. The heat sink 240 is a heat exchanger that cools the heat-generating component 130 by radiating heat absorbed from the heat-generating component 130 from the surface of the heat sink 240.

[0098] The heat sink body 240a is made of a metal with high thermal conductivity, such as aluminum, and is a generally plate-shaped member having a rectangular shape when viewed in the thickness direction. The heat sink body 240a is arranged so as to be thermally connected to the heat-generating component 130. In this embodiment, the heat sink body 240a is arranged so as to be in contact with the upper surface 131 of the body portion 134 of the heat-generating component 130.

[0099] A first straight pipe section 35a and a second straight pipe section 35b, which are parts of the liquid refrigerant pipe 35, are arranged on the upper surface 241 of the heat sink body 240a so as to be in contact with the heat sink body 240a. The first straight pipe section 35a and the second straight pipe section 35b are connected via a folded portion 35c, and the first straight pipe section 35a, the folded portion 35c, and the second straight pipe section 35b form a U-shape.

[0100] 10 and 12, the heat sink body 240a is formed with two second grooves 245 into which the first and second straight pipe sections 35a, 35b can be fitted. Grease to promote heat conduction is applied between the first and second straight pipe sections 35a, 35b and the second grooves 245. The cross section of the second grooves 245 is formed in a substantially arc shape, into which the first and second straight pipe sections 35a, 35b are fitted. This increases the contact area between the first and second straight pipe sections 35a, 35b and the heat sink body 240a.

[0101] During cooling operation, high-pressure refrigerant that has condensed or dissipated heat in the outdoor heat exchanger 23 (i.e., the refrigerant flowing between the outdoor heat exchanger 23 and the expansion valve 26) flows through the liquid refrigerant pipe 35. During heating operation, low-pressure refrigerant that has been decompressed by the expansion valve 26 (i.e., the refrigerant flowing between the expansion valve 26 and the outdoor heat exchanger 23) flows through the refrigerant pipe.

[0102] In this way, by arranging the heat-generating component 130 and the heat sink main body 240a, and the heat sink main body 240a and the liquid refrigerant piping 35 in contact with each other, when refrigerant flows through the liquid refrigerant piping 35, the refrigerant flowing through the first straight pipe section 35a and the second straight pipe section 35b cools the heat-generating component 130 via the pipe walls of the first straight pipe section 35a and the second straight pipe section 35b and the heat sink main body 240a.

[0103] The heat sink body 240a is also formed with a screw hole 243 that penetrates the thickness direction from the upper surface 241 to the lower surface 242 (the surface facing the substrate 110) of the heat sink body 240a. The screw hole 243 is a through-hole that does not have a thread. The screw hole 243 is formed in the central portion of the heat sink body 240a (more specifically, between one second groove portion 245 and the other second groove portion 245).

[0104] The cover 240b covers the heatsink body 240a and the first and second straight pipe portions 35a, 35b of the liquid refrigerant pipe 35 attached to the heatsink body 240a. The cover 240b has a rectangular shape when viewed in the thickness direction of the heatsink body 240a. The cover 240b is fixed to the heatsink body 240a with screws 248, for example.

[0105] (4) Features (4-1) The air conditioning device 1 of this embodiment includes a liquid refrigerant pipe 35 (a first straight pipe portion 35a and a second straight pipe portion 35b) through which a refrigerant flows, and any one of the electrical component modules 200 described in the first embodiment. The liquid refrigerant pipe 35 is in contact with a heat sink 240.

[0106] With this configuration, there is no need to provide screw holes in the substrate 110. As a result, it is easier to route the wiring on the substrate 110. Furthermore, because the screws 160 that pass through the heat sink 240 are fixed to the screw sockets 123 of the first member 120, it is possible to prevent the tips of the screws from coming into contact with the substrate 110.

[0107] (5) Modifications (5-1) Modification 2A In the present embodiment, the screw hole 243 is formed in the central portion of the heat sink body 240a (more specifically, between one second groove portion 245 and the other second groove portion 245). However, the screw hole 243 may be formed in the second groove portion 245. In this case, as shown in FIG. 13 , a recess 246 is further formed in the second groove portion 245. The recess 246 is configured so that when a screw 160 is inserted into the screw hole 243 from the upper surface 241 of the heat sink 240, and then passed through the screw hole 243 and the third hole 133 in this order, the screw 160 does not come into contact with the liquid refrigerant pipe 35 when the screw 160 is inserted into the screw hole 243 from the upper surface 241 of the heat sink 240, and then passed through the screw hole 243 and the third hole 133, and then inserted into the screw receiver 123 of the first member 120 and fastened.

[0108] In this modification, damage to the liquid refrigerant pipe 35 caused by the screw head can be suppressed.

[0109] (5-2) Variation 2B In this embodiment, the heat sink 240 has a heat sink main body 240a and a cover 240b, and the first straight pipe section 35a and the second straight pipe section 35b are arranged so as to contact the upper surface 241 of the heat sink main body 240a.

[0110] 14 , the heat sink 240 may have a second hole 244 that passes through the first straight pipe portion 35 a and the second straight pipe portion 35 b. The second hole 244 extends in the longitudinal direction of the heat sink 240, and the first straight pipe portion 35 a and the second straight pipe portion 35 b may be joined to the heat sink 240 by being press-fitted into the second hole 244. In this case, the screw 160 may be inserted into the screw hole 243 from the upper surface 241 of the heat sink 240, and the screw 160 that has passed through the screw hole 243 may be inserted into the screw receiver 123 of the first member 120 for fastening.

[0111] In this modification, the contact area between the first straight pipe portion 35a and the second straight pipe portion 35b and the heat sink 240 is increased, thereby improving the cooling performance of the heat sink 240 for the heat-generating component 130. Furthermore, since there is no need to attach a cover to cover the liquid refrigerant pipe 35, the efficiency of installation work can be improved.

[0112] (5-3) Modification 2C The heat sink 240 and the liquid refrigerant pipe 35 (the first straight pipe section 35a, the second straight pipe section 35b, and the folded-back section 35c) may be joined by soldering, brazing, crimping, or adhesive bonding.

[0113] In this modification, the contact area between the liquid refrigerant pipe 35 and the heat sink 240 is increased, thereby improving the cooling performance of the heat sink 240 for the heat-generating component 130. Furthermore, since there is no need to attach a cover to cover the liquid refrigerant pipe 35, the efficiency of installation work can be improved.

[0114] (5-4) Modification 2D A pressure reducing means may be provided between the outdoor heat exchanger 23 and the heat sink 240. This allows the refrigerant flowing through the liquid refrigerant pipe 35 (the first straight pipe section 35a and the second straight pipe section 35b) to be reduced to an intermediate-pressure refrigerant during cooling operation. As a result, the cooling performance of the heat sink 240 for the heat-generating component 130 can be improved.

[0115] Although the embodiments of the present disclosure have been described above, it will be understood that various changes in form and details can be made without departing from the spirit and scope of the present disclosure as defined in the claims.

[0116] DESCRIPTION OF SYMBOLS 1 Air conditioning apparatus, refrigeration cycle apparatus 35 Refrigerant piping, liquid refrigerant piping 35a Refrigerant piping, first straight pipe section 35b Refrigerant piping, second straight pipe section 100, 200 Electrical equipment module 110 Board 111 Mounting surface 112 First hole 120 First member 120a First member, eleventh member 120b First member, twelfth member 120c First member, thirteenth member 121, 121a, 121b, 121c First surface 123 Screw receiver 124 Positioning portion 127 Recess 130 Heat-generating component 130a First heat-generating component 130b Second heat-generating component 131, 131a, 131b Surface, upper surface 134 Main body portion 134a Main body portion, first main body portion 134b Main body portion, second main body portion 135, 135a, 135b Leads 140, 240 Heat sink 141, 241 Surface, upper surface 142, 242 Surface, lower surface 143, 243 Screw hole 150 Nut 160 Screw 244 Second hole

[0117] WO 2009 / 150804

Claims

1. A first heat-generating component (130, 130a) having a first body portion (134, 134a) and leads (135, 135a) extending from the first body portion; a substrate (110) having a mounting surface (111) on which the first heat-generating component is mounted; a heat sink (140, 240) thermally connected to the first heat-generating component and having a screw hole (143, 243) penetrating in the thickness direction; a first member (120, 120a, 120b, 120c) having a screw receiver (123) disposed between the mounting surface and the heat sink and fixed to the mounting surface; and a screw (160) inserted into the screw hole from a surface (141, 241) of the heat sink opposite to a surface (142, 242) facing the mounting surface, and fixed to the first member. Electrical equipment module (100, 200).

2. The electrical equipment module according to claim 1, wherein the substrate has a first hole (112) penetrating in the thickness direction, and the first member has a positioning portion (124) that is inserted into the first hole and determines the position of the first member relative to the mounting surface.

3. The electrical equipment module according to claim 2, wherein the diameter of the first hole is smaller than the diameter of the screw hole of the screw receiver.

4. The electrical equipment module according to any one of claims 1 to 3, wherein the first member further includes a nut (150) as a member constituting the screw receiver.

5. The electrical equipment module according to claim 4, wherein the first member further has a recess (127) on a first surface (121, 121a, 121b, 121c) facing the heat sink, in which the nut can be placed.

6. An electrical equipment module according to any one of claims 1 to 5, further comprising a second heat-generating component (130, 130b) mounted on the mounting surface, wherein the second heat-generating component has a second body portion (134, 134b) having a different height from the first body portion, and leads (135, 135b) extending from the second body portion, and the first member includes an eleventh member (120, 120a) and a twelfth member (120, 120b) having different heights, and by supporting the first body portion by the eleventh member and supporting the second body portion by the twelfth member, the positions of the surfaces (131, 131a, 131b) of the first and second heat-generating components mounted on the mounting surface that face the heat sink are aligned.

7. The electrical equipment module according to any one of claims 1 to 6, wherein a plurality of the first members are integrally molded.

8. A refrigeration cycle device (1), comprising: a refrigerant pipe (35, 35a, 35b) through which a refrigerant flows; and an electrical component module (200) according to any one of claims 1 to 7, wherein the refrigerant pipe is in contact with the heat sink.

9. The refrigeration cycle device according to claim 8, wherein the heat sink has a second hole (244) through which the refrigerant piping passes, and the refrigerant piping is joined to the heat sink while passing through the second hole.

10. A method for manufacturing a heat sink, comprising: a first step of arranging a first member (120, 120a, 120b, 120c) having a screw receptacle (123) on a mounting surface (111) of a substrate (110) on which a first heat-generating component (130, 130a) having a first main body portion (134, 134a) and leads (135, 135a) extending from the first main body portion is mounted; a second step of mounting the first heat-generating component on the mounting surface; a third step of arranging a heat sink (140, 240) having a screw hole (143, 243) penetrating in the thickness direction so as to be thermally connected to the first heat-generating component; and a fourth step of inserting a screw (160) into the screw hole from a surface (141, 241) of the heat sink opposite to a surface (142, 242) facing the mounting surface, to fix the heat sink to the first member. Manufacturing method for electrical equipment modules.

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