Control apparatus-integrated dynamoelectric machine

• US 8,299,666 B2
• Filed: 06/21/2010
• Issued: 10/30/2012
• Est. Priority Date: 01/18/2010
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Electric Corporation
• Inventors: Shirakata, Yuji, Nakajima, Dai, Fujita, Masahiko, Kato, Masaki, Sakamoto, Kazuyasu, Oga, Takuya
• Primary Examiner(s): NGUYEN, TRAN N
• Application Number:
  US12/819,678
• Publication Number:
  US 20110175496A1
• Time in Patent Office: 862 Days
• Field of Search: 310/64, 310/67.D, 310/68.R
• US Class Current: 310/68.R
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/48472 the other connecting portion not on the bonding area also being a wedge bond, i.e. wedge-to-wedge
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/13055 Insulated gate bipolar transistor [IGBT]
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2924/1815 Shape
• CPC Class Codes: H01L 2924/3511 Warping
• CPC Class Codes: H02K 11/05 Rectifiers associated with casings, enclosures or brackets
• CPC Class Codes: H02K 19/365 with a voltage regulator
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• CPC Class Codes: H02P 9/48 Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle H02P9/04 - H02P9/46 take precedence

Abstract

A dynamoelectric machine main body, power circuit modules and a field circuit module, and a control apparatus that has a heatsink that is prepared by die casting, and that is mounted integrally onto the dynamoelectric machine main body are included, the heatsink including a plurality of convex heat receiving portions that are disposed so as to project from a front surface of a base plate, and that have heat receiving surfaces, the power circuit modules and the field circuit module including seal main body portions that are constituted by an electrically insulating resin that seal switching elements so as to expose bottom surfaces of element heat radiating portions on reference surfaces that have a surface shape that corresponds to a shape of the heat receiving surfaces, and electrical insulation supporting layers being interposed between the bottom surfaces of the heat receiving surfaces and the element heat radiating portions.

Claims

1. A control apparatus-integrated dynamoelectric machine comprising:

a dynamoelectric machine main body comprising;

a stator that has an armature winding;

a rotor that has a field winding; and

a housing that supports said stator and said rotor; and

a control apparatus that is mounted integrally onto said dynamoelectric machine main body, said control apparatus comprising;

a power circuit module and a field circuit module that respectively supply electric power to said armature winding and said field winding, said power circuit module and said field circuit module each comprising;

a flat element heat radiating portion that is made of a metal; and

a switching element that is mounted to a front surface of said element heat radiating portion;

a heatsink that is prepared by die casting, said power circuit module and said field circuit module are mounted on said heatsink; and

a switching element controlling means that controls said switching elements, wherein;

said heatsink comprises a base plate; and

a plurality of convex heat receiving portions that are each disposed so as to project from a front surface of said base plate, projecting end surfaces that constitute heat receiving surfaces, and said power circuit module and said field circuit module are respectively mounted to each of said heat receiving surfaces;

said power circuit module and said field circuit module each comprise a seal main body portion that is made of an electrically insulating resin that seals said switching element so as to expose a bottom surface of said element heat radiating portion at a reference surface that has a surface shape that corresponds to a shape of said heat receiving surface, said power circuit module and said field circuit module each being disposed such that said bottom surface of said element heat radiating portion is oriented toward said heat receiving surface;

an electrical insulation supporting layer is interposed between said heat receiving surface and said bottom surface of said element heat radiating portion; and

an electrically insulating lug that is made of an electrically insulating material is configured integrally into said seal main body portion and projects toward said heat receiving surface from said reference surface, and a projecting length of said electrically insulating lug from said reference surface is set such that said electrical insulation supporting layer ensures electrical insulation between said heat receiving surface and said bottom surface of said element heat radiating portion, and has a heat radiating performance such that heat from said switching elements is radiated to said convex heat receiving portions such that the temperature of said switching elements does not exceed a predefined permissible upper limit temperature, when said power circuit module and said field circuit module are disposed so as to place said electrically insulating lug in contact with said heat receiving surface.

2. A control apparatus-integrated dynamoelectric machine according to claim 1, wherein:

an interfitting recess portion that has an opening inside a region of said heat receiving surface that faces a projecting end of said electrically insulating lug is formed on said convex heat receiving portion; and

a positioning salient portion that is made of an electrically insulating material, and that can be fitted together with said interfitting recess portion is disposed so as to project from said electrically insulating lug.

3. A control apparatus-integrated dynamoelectric machine according to claims 1, wherein:

a heat receiving portion surrounding lug that is made of an electrically insulating material is configured integrally with said seal main body portion and projects toward said base plate from said reference surface so as to surround a predetermined range of said convex heat receiving portion from a leading end toward a base end portion; and

a first end of a metal lead terminal is embedded in said seal main body portion and said heat receiving portion surrounding lug that have been integrated, and a second end portion of said metal lead terminal extends outward from said seal main body portion and said heat receiving portion surrounding lug that have been integrated.

7. A control apparatus-integrated dynamoelectric machine according to claims 1, wherein:

said power circuit module comprises an upper arm and a lower arm that each have a switching element, and that are connected such that said switching elements are in series; and

said upper arm and said lower arm are sealed into an identical seal main body portion.

4. A control apparatus-integrated dynamoelectric machine comprising:

a dynamoelectric machine main body comprising;

a stator that has an armature winding;

a rotor that has a field winding; and

a housing that supports said stator and said rotor; and

a control apparatus that is mounted integrally onto said dynamoelectric machine main body, said control apparatus comprising;

a power circuit module and a field circuit module that respectively supply electric power to said armature winding and said field winding, said power circuit module and said field circuit module each comprising;

a flat element heat radiating portion that is made of a metal; and

a switching element that is mounted to a front surface of said element heat radiating portion;

a heatsink that is prepared by die casting, said power circuit module and said field circuit module are mounted on said heatsink; and

a switching element controlling means that controls said switching elements, wherein;

said heatsink comprises a base plate; and

a plurality of convex heat receiving portions that are each disposed so as to project from a front surface of said base plate, projecting end surfaces that constitute heat receiving surfaces, and said power circuit module and said field circuit module are respectively mounted to each of said heat receiving surfaces;

said power circuit module and said field circuit module each comprise a seal main body portion that is made of an electrically insulating resin that seals said switching element so as to expose a bottom surface of said element heat radiating portion at a reference surface that has a surface shape that corresponds to a shape of said heat receiving surface, said power circuit module and said field circuit module each being disposed such that said bottom surface of said element heat radiating portion is oriented toward said heat receiving surface;

an electrical insulation supporting layer is interposed between said heat receiving surface and said bottom surface of said element heat radiating portion;

a heat receiving portion surrounding lug that is made of an electrically insulating material is configured integrally with said seal main body portion and projects outward from said reference surface so as to surround an entire region in a direction of projection of said convex heat receiving portion from said base plate and be placed in contact with said base plate; and

a projecting length of said heat receiving portion surrounding lug from said reference surface is set such that said electrical insulation supporting layer ensures electrical insulation between said heat receiving surface and said bottom surface of said element heat radiating portion, and has a heat radiating performance such that heat from said switching elements is radiated to said convex heat receiving portions such that a temperature of said switching elements does not exceed a predefined permissible upper limit temperature, when said power circuit module and said field circuit module are disposed so as to place a leading end of said heat receiving portion surrounding lug in contact with said base plate.

5. A control apparatus-integrated dynamoelectric machine according to claim 4, wherein:

an interfitting recess portion that has an opening inside a region of said base plate that faces a projecting end of said heat receiving portion surrounding lug is formed on said base plate; and

a positioning salient portion that is made of an electrically insulating material, and that can be fitted together with said interfitting recess portion is disposed so as to project from said heat receiving portion surrounding lug.

6. A control apparatus-integrated dynamoelectric machine according to claim 5, wherein a first end of a metal lead terminal is embedded in said seal main body portion and said heat receiving portion surrounding lug that have been integrated, and a second end portion of said metal lead terminal extends outward from said seal main body portion and said heat receiving portion surrounding lug that have been integrated.