Power converter

• US 9,210,834 B2
• Filed: 03/15/2013
• Issued: 12/08/2015
• Est. Priority Date: 01/17/2006
• Status: Active Grant

• Current Assignee: Hitachi Astemo Ltd. (Hitachi, Ltd.)
• Original Assignee: Hitachi, Ltd.
• Inventors: Nakatsu, Kinya, Saito, Ryuichi, Suga, Takashi, Funato, Hiroki, Nakamura, Takayoshi
• Primary Examiner(s): Haughton, Anthony
• Assistant Examiner(s): Gafur, Razmeen
• Application Number:
  US13/837,423
• Publication Number:
  US 20130223009A1
• Time in Patent Office: 998 Days
• Field of Search: 361676-678, 36167946-67954, 361688-723, 361/679.47, 361/679.52, 361/679.53, 165 801- 805, 165/104.33, 165/185, 174 151- 153, 174 161- 163, 174/547, 174/548, 256712-722, 256/E23.088, 363/141, 454/184, 312/236
• US Class Current: 1/1
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/42 with use of more than one motor
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/525 Temperature of converter or components thereof
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: H01L 2224/48139 with an intermediate bond, e.g. continuous wire daisy chain
• CPC Class Codes: H01L 2224/49175 Parallel arrangements
• CPC Class Codes: H01L 2924/19107 off-chip wires
• CPC Class Codes: H02M 7/003 : Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/2089 : for power electronics, e.g. for inverters for controlling motor
• CPC Class Codes: H05K 7/20927 : Liquid coolant without phase change
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

The object is to provide a power converter which is capable of minimizing an extent to which the power converter components other than the semiconductor module are thermally affected by the heat originating from the semiconductor module. The semiconductor modules constituting a main circuit for power conversion; a capacitor electrically connected to the main circuit; drive circuits that provide the main circuit with a drive signal used in power conversion operation; a control circuit that provides the drive circuit with a control signal used to prompt the drive circuit to provide the drive signal. Within a casing, a cooling chamber including a coolant passage is formed, and a chamber wall of the cooling chamber is formed with a thermally conductive material. At least the semiconductor modules are housed inside the cooling chamber, and at least the capacitor and the control circuit are disposed outside the cooling chamber.

Claims

1. A power converter, comprising:

a semiconductor module that comprises a power semiconductor element to convert DC power to AC power;

a capacitor for smoothing the DC power;

a DC-side connecting conductor that transmits the DC power from the capacitor to the semiconductor module;

a passage forming body that is constructed of a thermally conductive member and forms a passage through which coolant flows; and

a case that defines a housing space for housing the semiconductor module and is provided with an opening portion, wherein;

the semiconductor module is disposed at one side of the passage forming body and the capacitor is disposed at another side of the passage forming body, opposite to the semiconductor module via the passage forming body;

the passage forming body is provided with an opening that communicates with the passage at the side of the passage forming body where the semiconductor module is disposed and a through hole that connects between a space in which the semiconductor module is disposed and a space in which the capacitor is disposed;

the semiconductor module is provided with a heat transfer plate on which the power semiconductor element is mounted via an insulating substrate;

the heat transfer plate closes the opening so as to directly contact with the coolant;

the opening portion of the case is closed by the passage forming body in a state in which the semiconductor module is housed in the housing space of the case; and

the DC-side connecting conductor extends through the through hole to electrically connect the capacitor with the semiconductor module.

2. A power converter according to claim 1, wherein:

the capacitor is disposed at the other side of the passage forming body and is in contact with the passage forming body.

3. A power converter according to claim 1, wherein:

the DC-side connecting conductor comprises a plate-like positive capacitor terminal, a plate-like negative capacitor terminal facing to the positive capacitor terminal, and an insulation member disposed between the positive capacitor terminal and the negative capacitor terminal.

4. A power converter according to claim 1, wherein:

the semiconductor module comprises a plate-like positive module terminal and a plate-like negative module terminal;

the DC-side connecting conductor comprises a plate-like positive capacitor terminal, a plate-like negative capacitor terminal;

the positive capacitor terminal and the negative capacitor terminal protrude through the through hole into the space in which the semiconductor module is disposed;

the positive module terminal extends along a direction in which the positive capacitor terminal protrudes, and is connected with the positive capacitor terminal; and

the negative module terminal extends along a direction in which the negative capacitor terminal protrudes, and is connected with the negative capacitor terminal.

5. A power converter according to claim 1, further comprising:

a control circuit board on which a control circuit for controlling drive of the power semiconductor element is mounted, wherein;

the control circuit board is disposed outside the housing space of the case for housing the semiconductor module and housed in a case other than the case for housing the semiconductor module.

6. A power converter according to claim 1, wherein:

the power semiconductor module comprises a plurality of U-phase power semiconductor elements that constitutes a U-phase, a plurality of V-phase power semiconductor elements that constitutes a V-phase, and a plurality of W-phase power semiconductor elements that constitutes a W-phase, a first plate-like positive module terminal disposed at closer the plurality of U-phase power semiconductor elements than the plurality of V-phase power semiconductor elements and the plurality of W-phase power semiconductor elements, a second plate-like positive module terminal disposed at closer the plurality of V-phase power semiconductor elements than the plurality of U-phase power semiconductor elements and the plurality of W-phase power semiconductor elements, a third plate-like positive module terminal disposed at closer the plurality of W-phase power semiconductor elements than the plurality of U-phase power semiconductor elements and the plurality of V-phase power semiconductor elements.

7. A power converter according to claim 1, further comprising:

an AC bus bar that transmits the AC power, wherein

the passage forming body is provided with a second through hole, and

the AC bus bar extends through the second through hole to be electrically connected with the semiconductor module.

8. A power converter according to claim 1, further comprising:

the heat transfer plate provides cooling fin.