Power conversion apparatus

• US 8,582,291 B2
• Filed: 02/07/2011
• Issued: 11/12/2013
• Est. Priority Date: 02/05/2010
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Nakasaka, Akira, Oohama, Kenichi
• Primary Examiner(s): SMITH, COURTNEY L
• Application Number:
  US13/021,926
• Publication Number:
  US 20110194247A1
• Time in Patent Office: 1,009 Days
• Field of Search: 36167946-67947, 36167952-67954, 361688-690, 361698-704, 361/707, 361715-718, 361/725, 361/728, 361763-764, 361/821, 361829-832
• US Class Current: 361/679.47
• CPC Class Codes: H01L 23/40 Mountings or securing means for detachable cooling or heating arrangements heating H01L23/345; fixed by friction, plugs or springs
• CPC Class Codes: H01L 23/4012 for stacked arrangements of a plurality of semiconductor devices assemblies per se H01L25/00
• CPC Class Codes: H01L 23/4093 Snap-on arrangements, e.g. clips
• CPC Class Codes: H01L 23/473 by flowing liquids H01L23/4332, H01L23/4338 take precedence
• 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 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20854 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20863 takes precedence
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

In a power conversion apparatus, electronic components and a cooler are integrated in a frame as an internal unit. The internal unit is fixed within a case through the frame. The frame has such a shape that the electronic components are surrounded by the frame, and includes a first wall section, and second and third wall sections extending from both sides of the first wall section. The cooler includes a coolant introduction tube and a coolant discharge tube. The coolant introduction tube and the coolant discharge tube project outward from to the frame. The first to third wall sections include a support wall section supporting at least one of the coolant introduction tube and the coolant discharge tube, and a frame wall section not supporting the coolant introduction tube and the coolant discharge tube. The thickness of the support wall section is larger than the thickness of the frame wall section.

Claims

1. A power conversion apparatus comprising:

electronic components that form at least part of a power conversion circuit;

a cooler for cooling at least part of the electronic components;

a case that surrounds and encloses the electronic components and the cooler; and

a frame that is attached to an interior of the case

wherein

the at least part of the electronic components and the cooler are fixed to and integrated with the frame to form an internal unit,

the frame is formed so as to surround the at least part of the electronic components that form at least part of the internal unit, and includes at least a front wall section, and a pair of side wall sections that extend backward from both ends of the front wall section,

the cooler includes a coolant introduction tube introducing coolant into the cooler and a coolant discharge tube discharging the coolant from the cooler, the coolant introduction tube and the coolant discharge tube projecting outward from the frame while being supported by the front wall section, and

the thickness of the front wall section is larger than the thickness of the side wall section.

2. The power conversion apparatus according to claim 1, wherein the front wall section is provided with a pair of tube concave portions in which the coolant introduction tube and the coolant discharge tube are respectively disposed.

3. The power conversion apparatus according to claim 2, wherein the front wall section contacts a front surface of the cooler at a central portion between the pair of tube concave portions, and a forming area of the front surface of the cooler falls within a forming area of the central portion in the height direction which is perpendicular to the direction in which the pair of tube concave portions are arranged and the direction in which the coolant introduction tube and the coolant discharge tube project.

4. The power conversion apparatus according to claim 3, wherein

the coolant introduction tube and the coolant discharge tube are held by clamping members with respect to the front wall section,

the front wall section has lateral adjacent portions at positions adjacent to the pair of tube concave portions and at the sides of the side wall sections, and

end faces of the lateral adjacent portions closer to the opening sides of the tube concave portions are recessed with respect to the central portion.

5. The power conversion apparatus according to claim 1, wherein

the coolant introduction tube and the coolant discharge tube are held by clamping members with respect to the front wall section, and

the front wall section includes threaded holes, into which fixing screws for fixing the clamping members are screwed, and engaged portions in which engaging portions for stopping turn of the clamping members are engaged.

6. The power conversion apparatus according to claim 1, wherein the frame includes a rear wall section which joins the pair of side wall sections at rear ends thereof, and surrounds the at least part of the electronic components configuring the internal unit from four sides.

7. The power conversion apparatus according to claim 6, wherein

the internal unit includes semiconductor modules, which incorporate switching elements, as the electronic components,

the cooler includes cooling tubes each having therein a coolant passage,

the internal unit incorporates a stacked body in which the cooling tubes and the semiconductor modules are stacked alternately,

the internal unit includes a pressure member pressing the stacked body in the stacking direction, and

the pressure member is interposed between the rear wall section and a rear end in the stacked direction of the stacked body, and a front end in the stacked direction of the stacked body is supported by the front wall section.

8. The power conversion apparatus according to claim 7, wherein

the rear wall section includes a planar rear contact surface which the pressure member contacts,

the front wall section includes a planar front contact surface which the front end in the stacked direction of the stacked body contacts, and

the rear contact surface and the front contact surface are parallel to each other.

9. The power conversion apparatus according to claim 8, wherein the front contact surface projects from the inner surface of the front wall section around therearound to the stacked body.

10. The power conversion apparatus according to claim 8, wherein the front wall section includes a front outer side surface parallel to the front contact surface at the outer side surface thereof.

11. The power conversion apparatus according to claim 1, wherein

the frame is configured by providing component fixing sections, that fix part of the electronic components configuring the power conversion circuit, at both sides in the height direction perpendicular to both the longitudinal directions of the front wall section and the rear wall section and the longitudinal directions of the side wall sections, and

at least one of the component fixing sections is disposed at each of the sides in the height direction of the front wall section.

12. The power conversion apparatus according to claim 11, wherein at least one of the component fixing sections is disposed at each of the sides in the height direction of the rear wall section.

13. The power conversion apparatus according to claim 1, wherein

the coolant introduction tube and the coolant discharge tube are provided so as to project from the case,

annular packing is disposed between both the coolant introduction tube and the coolant discharge tube and the case, the annular packing sealing clearances between both the coolant introduction tube and the coolant discharge tube and the case, and

the outer side surface of the front wall section has recessed surfaces, which are recessed backward, at positions opposed to the annular packing.

14. The power conversion apparatus according to claim 1, wherein

at least part of the front wall section is formed by an H-shaped wall section having a substantially H-shaped cross section, the H-shaped wall section being configured with a pair of longitudinal plate sections perpendicular to the stacking direction, and a connecting section connecting the pair of longitudinal plate sections together at the center of the pair of longitudinal plate sections, and

the H-shaped wall section is configured by partially providing ribs which are orthogonal to the longitudinal plate sections and the connecting section, between the pair of longitudinal plate sections and the connecting section.

15. A power conversion apparatus comprising:

electronic components that form at least part of a power conversion circuit;

a cooler for cooling at least part of the electronic components; and

a case housing the electronic components and the cooler;

wherein

the at least part of the electronic components and the cooler are fixed to and integrated in a frame to form one internal unit,

the internal unit is fixed within the case through the frame,

the frame is formed so as to surround the at least part of the electronic components that form at least part of the internal unit, and includes at least a front wall section, and a pair of side wall sections that extend backward from both ends of the front wall section,

the cooler includes a coolant introduction tube introducing coolant into the cooler and a coolant discharge tube discharging the coolant from the cooler, the coolant introduction tube and the coolant discharge tube projecting outward from the frame while being supported by the front wall section,

the thickness of the front wall section is larger than the thickness of the side wall section, and

the front wall section is provided with a pair of tube concave portions in which the coolant introduction tube and the coolant discharge tube are respectively disposed.

16. The power conversion apparatus according to claim 15, wherein the front wall section contacts a front surface of the cooler at a central portion between the pair of tube concave portions, and a forming area of the front surface of the cooler falls within a forming area of the central portion in the height direction which is perpendicular to the direction in which the pair of tube concave portions are arranged and the direction in which the coolant introduction tube and the coolant discharge tube project.

17. The power conversion apparatus according to claim 16, wherein:

the coolant introduction tube and the coolant discharge tube are held by clamping members with respect to the front wall section,

the front wall section has lateral adjacent portions at positions adjacent to the pair of tube concave portions and at the sides of the side wall sections, and

end faces of the lateral adjacent portions closer to the opening sides of the tube concave portions are recessed with respect to the central portion.

18. A power conversion apparatus comprising:

electronic components that form at least part of a power conversion circuit;

a cooler for cooling at least part of the electronic components; and

a case housing the electronic components and the cooler;

wherein

the at least part of the electronic components and the cooler are fixed to and integrated in a frame to form one internal unit,

the internal unit is fixed within the case through the frame,

the frame is formed so as to surround the at least part of the electronic components that form at least part of the internal unit, and includes at least a front wall section, and a pair of side wall sections that extend backward from both ends of the front wall section,

the cooler includes a coolant introduction tube introducing coolant into the cooler and a coolant discharge tube discharging the coolant from the cooler, the coolant introduction tube and the coolant discharge tube projecting outward from the frame while being supported by the front wall section,

the thickness of the front wall section is larger than the thickness of the side wall section,

the coolant introduction tube and the coolant discharge tube are held by clamping members with respect to the front wall section, and

the front wall section includes threaded holes, into which fixing screws for fixing the clamping members are screwed, and engaged portions in which engaging portions for stopping turn of the clamping members are engaged.

19. A power conversion apparatus comprising:

electronic components that form at least part of a power conversion circuit;

a cooler for cooling at least part of the electronic components; and

a case housing the electronic components and the cooler;

wherein

the at least part of the electronic components and the cooler are fixed to and integrated in a frame to form one internal unit,

the internal unit is fixed within the case through the frame,

the frame is formed so as to surround the at least part of the electronic components that form at least part of the internal unit, and includes at least a front wall section, and a pair of side wall sections that extend backward from both ends of the front wall section,

the cooler includes a coolant introduction tube introducing coolant into the cooler and a coolant discharge tube discharging the coolant from the cooler, the coolant introduction tube and the coolant discharge tube projecting outward from the frame while being supported by the front wall section,

the thickness of the front wall section is larger than the thickness of the side wall section,

the frame includes a rear wall section which joins the pair of side wall sections at rear ends thereof, and surrounds the at least part of the electronic components configuring the internal unit from four sides,

the internal unit includes semiconductor modules, which incorporate switching elements, as the electronic components,

the cooler includes cooling tubes each having therein a coolant passage,

the internal unit incorporates a stacked body in which the cooling tubes and the semiconductor modules are stacked alternately,

the internal unit includes a pressure member pressing the stacked body in the stacking direction, and

the pressure member is interposed between the rear wall section and a rear end in the stacked direction of the stacked body, and a front end in the stacked direction of the stacked body is supported by the front wall section.

20. The power conversion apparatus according to claim 19, wherein

the rear wall section includes a planar rear contact surface which the pressure member contacts,

the front wall section includes a planar front contact surface which the front end in the stacked direction of the stacked body contacts, and

the rear contact surface and the front contact surface are parallel to each other.

21. The power conversion apparatus according to claim 20, wherein the front contact surface projects from the inner surface of the front wall section therearound to the stacked body.

22. The power conversion apparatus according to claim 20, wherein the front wall section includes a front outer side surface parallel to the front contact surface at the outer side surface thereof.

23. A power conversion apparatus comprising:

electronic components that form at least part of a power conversion circuit;

a cooler for cooling at least part of the electronic components; and

a case housing the electronic components and the cooler;

wherein

the at least part of the electronic components and the cooler are fixed to and integrated in a frame to form one internal unit,

the internal unit is fixed within the case through the frame,

the frame is formed so as to surround the at least part of the electronic components that form at least part of the internal unit, and includes at least a front wall section, and a pair of side wall sections that extend backward from both ends of the front wall section,

the cooler includes a coolant introduction tube introducing coolant into the cooler and a coolant discharge tube discharging the coolant from the cooler, the coolant introduction tube and the coolant discharge tube projecting outward from the frame while being supported by the front wall section,

the thickness of the front wall section is larger than the thickness of the side wall section,

at least part of the front wall section is formed by an H-shaped wall section having a substantially H-shaped cross section, the H-shaped wall section being configured with a pair of longitudinal plate sections perpendicular to the stacking direction, and a connecting section connecting the pair of longitudinal plate sections together at the center of the pair of longitudinal plate sections, and

the H-shaped wall section is configured by partially providing ribs which are orthogonal to the longitudinal plate sections and the connecting section, between the pair of longitudinal plate sections and the connecting section.