JP3334620B2 - DC-DC converter device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a DC-DC converter for converting high-voltage DC power to low-voltage DC power and converting low-voltage DC power to high-voltage DC power.

[0002]

2. Description of the Related Art As conventionally known, DC-D
The C converter circuit includes an inverter circuit that converts input DC power into AC power, a transformer that changes the output voltage of the inverter circuit, a rectifier circuit that rectifies the output of the transformer, and an output that smoothes the output voltage of the rectifier circuit. It has a smoothing circuit. It is also common to provide an input smoothing circuit for smoothing the input current of the inverter circuit.

A power switching element of an inverter circuit among the above elements constituting a DC-DC converter circuit is fixed to a wiring board through a metal member for cooling or heat sink, and other circuit parts constituting the DC-DC converter circuit are: It is usually mounted on a wiring board.

[0004]

However, DC-DC
Of the circuit components that make up the converter circuit, transformers and choke coils have a higher height than other circuit components, so the busbar shape that connects the terminals of these transformers and choke coils to other circuit components However, there is a problem that the required space is increased.

Further, since these transformers or choke coils are heavier than other circuit components, it is necessary to improve the strength of a wiring board that supports them.
Further, there is a problem that the life of the transformer or the choke coil is also limited due to the heat generation. The present invention has been made in view of the above problems, the routing of the bus bar is simple, it is not necessary to improve the strength of the wiring board,
DC that can extend the life of transformer or choke coil
It is an object thereof to provide a DC converter device.

[0006]

A DC-D according to claim 1.
In the C converter device, the metal member that supports and cools the power switching element of the inverter circuit and that supports the wiring board is parallel to the anti-mounting surface while facing the anti-mounting surface of the wiring board at a predetermined interval. It has a parallel plate portion that is extended. The bottom surface of the transformer or the choke coil is provided in close contact with the main surface of the parallel plate portion on the wiring board side, and protrudes from the hole or cutout provided in the wiring board to the mounting surface side of the wiring board. This allows the terminals of the transformer or the choke coil to protrude above the mounting surface of the wiring board and to be easily connected to the connection terminals on the wiring board.

More specifically, the height of the terminal of the transformer or the choke coil can be lowered through the hole provided in the transformer or the choke coil to the parallel plate portion thereunder. The connection terminals provided on the wiring board can be vertically overlapped with the terminals of the transformer or choke coil without raising the height of these connection terminals above the wiring board. The arrangement of the bus bars is particularly low and particularly simple in its height direction.

Further, the hole into which the transformer or the choke coil is inserted can be opened near the connection terminal fixed to the wiring board, so that the transformer or the choke coil can be positioned on the outer periphery of the wiring board. Compared to the case where the wiring board is provided on a parallel plate or a metal member, the wiring (usually a bus bar) for connecting the connection terminal to the circuit component on the wiring board can be shortened and a simple shape can be obtained. Thereby, the resistance loss and the weight of the wiring can be reduced.

Further, as described above, the terminals of the transformer or the choke coil and the connection terminals can be easily overlapped with each other up and down, so that they can be fastened by screws from above. All operations can be easily performed from above, and the assembling work can be easily automated and simplified. In addition, the hole for inserting the transformer or the choke coil provided on the wiring board can be used as a guide for positioning the transformer or the choke coil, and in some cases , the transformer or the choke coil may move in the lateral direction. It can also have a function as a blocking member against this.

In addition, since it is not necessary to mount a transformer or a choke coil on the wiring board while maintaining the convenience of connection with connection terminals suitably provided at suitable positions on the wiring board, the strength and rigidity of the wiring board are reduced. There is also an advantage that the increase in the number is not required. Further, since the heat generated in the transformer or the choke coil is satisfactorily radiated to the parallel plate portion of the metal member, the life of the transformer or the choke coil can be improved.

Further, the parallel plate portion of the metal member has a large heat dissipation surface area, is effective for heat dissipation of the power switching element, and can also protect the wiring substrate by covering the rear surface thereof. According to the configuration of claim 2, in the DC-DC converter device of claim 1, the terminals of the transformer or the choke coil are extended in parallel with the mounting surface and fastened to the connection terminals. In this way, wiring,
Connection work is simplified.

For example, as connection terminals of a wiring board,
The female screw hole provided in the terminal block or the bus bar can be used, and the wiring can be completed only by overlapping the play hole of the transformer or the choke coil on this and fastening the screw from above. Conversely, a transformer or a choke coil is set on the parallel plate in advance, and the wiring board is dropped from above, so that the connection terminal of the wiring board is superimposed on the terminal of the transformer or the choke coil. Good.

According to a third aspect of the present invention, in the DC-DC converter device according to the first or second aspect, further, a pair of side plate portions erected from the wiring board along side surfaces of the rectangular core of the transformer or the choke coil. And a top-shaped core holding plate having a top plate provided between the front ends of both side plate portions and in close contact with the top surface of the rectangular core. With this configuration, the transformer or the choke coil can be easily fixed.

According to a fourth aspect of the present invention, in the DC-DC converter according to the third aspect, the top plate further comprises:
The central portion curves toward the transformer or choke coil side to elastically bias the transformer or choke coil toward the parallel plate portion of the base plate. With this configuration, the transformer or the choke coil can be more easily fixed by the core holding plate.

According to a fifth aspect of the present invention, in the DC-DC converter according to the first or fourth aspect, further, the base plate is perpendicular to the parallel plate portion from one side of the parallel plate portion toward the wiring board. The power switching element has a power switching element support plate that is erected, and the power switching element is protruded from the power switching element support plate toward the wiring board.

According to this configuration, the short power switching element can be positioned on the circuit component mounting surface side of the wiring board while being fixed to the metal member, and the wiring can be simplified. According to the configuration of claim 6, according to claim 4,
In the DC-DC converter device according to
The board is erected from the parallel plate portion and the wiring board is placed thereon.
To the plurality of wiring board support projections
A) The both side plate portions of the holding plate are provided with holes in the wiring board.
And is fastened to the screw hole of the wiring board supporting protrusion.
Characterized by being fixed to the wiring board by screws
I have. According to the configuration of claim 7, the DC of claim 1 is provided.
-In the DC converter device, the parallel plate portion may further include:
The core of the transformer or choke coil is mounted
A pedestal portion, wherein the pedestal portion is the transformer or
The terminals of the work coil to the connection terminals on the wiring board.
It is characterized by having a height that can be worn. Claim
According to the configuration of claim 8, the DC-DC converter according to claim 1 is provided.
In the barter apparatus, the parallel plate portion may further include the transformer.
Has a wall that abuts the bottom of the side of the coil or choke coil.
It is characterized by doing.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the DC-DC converter according to the present invention will be described with reference to the following embodiments.

[0018]

Embodiment 1 First Embodiment of DC-DC Converter Device of the Present Invention
An embodiment will be described with reference to FIG. FIG. 1 shows this DC-
It is a circuit diagram of a DC converter device. This DC-DC converter device is for converting a main battery (not shown) for storing running energy of an electric vehicle to an auxiliary device and an auxiliary device battery for supplying power to a control device, and for supplying power. An input smoothing circuit 1 connected to a DC power supply (not shown) for smoothing the current, an inverter circuit 2 for converting DC power input from the input smoothing circuit 1 to AC power, and changing an output voltage of the inverter circuit 2 And an inverter circuit having a full-wave rectifier circuit module 4 for rectifying the output of the transformer 3 and an output smoothing circuit 5 for smoothing the output voltage of the full-wave rectifier circuit module 4 as its main components. The output smoothing circuit 5 further includes a controller for controlling the inverter circuit 2, a current sensor, and the like. The output smoothing circuit 5 includes a smoothing capacitor 6 and a choke coil 7.

Further, this DC-DC converter device has
As shown in FIG. 2 which is a perspective view, a wiring board 8 and a base plate (metal member in the present invention) 9 for mounting the above components and circuit elements are provided. On the mounting surface of the wiring board 8, a large number of busbars 1 are sewn between the components and circuit elements.
0 is extended. As is well known, the inverter circuit 2 includes four IGBT modules (power switching elements)
Each of the IGBT modules 11 has an IGBT and a flyback diode connected in anti-parallel.

The wiring substrate 8 is a multilayer alumina substrate on which components and circuit elements other than the full-wave rectifier circuit module 4, the IGBT module 11, the transformer 3, and the choke coil 7 are mounted on the mounting surface. To mount each component or circuit element on the wiring board 8, as shown in FIG. 4, terminals are inserted into holes provided in the wiring board 8, and soldering is performed on the non-mounting surface side of the wiring board 8. .

The base plate 9 is an aluminum member, and is a thick plate-shaped parallel plate portion 91 which is proximate to the non-mounting surface of the wiring board 8 and extends in parallel with the mounting surface. It comprises a linear projection 92 erected at right angles to the parallel plate 91 toward the substrate 8 and a power switching element support plate 93. Power switching element support plate 93
Indicates that each I of the inverter circuit 2 is
A heat sink on which the GBT module 11 is mounted, which is fastened to the top surface of the linear projection 92 by a screw 94;
As a result, the parallel plate portion 91 of the base plate 9 faces the non-mounting surface of the wiring board 8 at a predetermined interval. Therefore, the parallel plate portion 91 of the base plate 9 has a case function of protecting the non-mounting surface of the wiring board 8 and also has a function as a heat sink of the IGBT module 11.

One side of the wiring board 8 is fastened to a wiring board supporting projection 95 extending from the power switching element support plate 93 to the wiring board 8 side in parallel with the wiring board 8. The base plate 9 also functions to support the wiring board 8 by being fastened to the wiring board supporting projection 96 erected from the parallel plate portion 91 toward the wiring board 8 side.

As shown in FIGS. 3 and 4, the wiring board 8 has a hole 81 for inserting the transformer 3 and a notch 82 for inserting the full-wave rectifier circuit module 4 and the choke coil 7.
Are provided. The transformer 3 is inserted into the hole 81, and the bottom surface thereof is seated on a transformer base 97 projecting from the upper surface of the parallel plate 91. The full-wave rectifier circuit module 4 is inserted into the notch 82, and the bottom surface thereof is seated on a pedestal 98 projecting from the upper surface of the parallel plate 91. The choke coil 7 is inserted into the notch 82 adjacent to the full-wave rectifier circuit module 4, and the bottom surface thereof is seated on a pedestal 99 projecting from the upper surface of the parallel plate 91. That is, the base plate 9 has a function of carrying the transformer 3 and the choke coil 7 which are heavy components, and the full-wave rectifier circuit module 4 which is a large heat generating component.
It also has the function of supporting and radiating heat.

The full-wave rectifier circuit module 4 is fastened to a screw hole formed on the pedestal 98, but since the transformer 3 and the lower part of the choke coil 7 are cores, the pedestal 97,
99 not concluded. The heights of the pedestals 97 to 99 are different from each other, and the terminals of the full-wave rectification circuit module 4, the transformer 3, and the choke coil 7 mounted thereon are connected to the wiring board 8 for fastening. It can overlap with the bus bar 10 above the mounting surface.

The transformer 3 has a tripod-shaped core 30 around which a primary coil and a secondary coil are wound, and a core pressing plate 31 is put on the tripod-shaped core 30. The core holding plate 31 is formed of a pair of side plates 31 erected from the wiring board 8 along the side surface of the tripod core 30.
1 is a gate-shaped sheet metal member having a top plate portion 312 provided between the distal ends of both side plate portions 311 and in close contact with the top surface of the tripod core 30. The both side plate portions 311 are fastened to the parallel plate portion 91 of the base plate 9 by screws penetrating the wiring board 8, whereby the transformer 3 is fixed to the wiring board 8 and the base plate 9. The top plate portion 312 has a central portion curved toward the transformer 3 side to elastically urge the transformer 3 toward the parallel plate portion 91 of the base plate 9.

The choke coil 7 has a tripod-shaped core 70 around which a coil is wound, and a core pressing plate 71 is put on the tripod-shaped core 70. The core holding plate 71 is provided between a pair of side plate portions 711 erected from the wiring board 8 along the side surface of the tripod core 70 and the front ends of the both side plate portions 711 and is in close contact with the top surface of the tripod core 70. And a top plate portion 712. The both side plate parts 711 are fastened to the parallel plate part 91 of the base plate 9 by screws penetrating the wiring board 8, whereby the choke coil 7 is fixed to the wiring board 8 and the base plate 9. The top plate portion 712 has a central portion curved toward the choke coil 7 side and elastically biases the choke coil 7 toward the parallel plate portion 91 of the base plate 9.

Next, the order of assembling the main parts of the DC-DC converter will be described below. First, necessary components and circuit elements are mounted, and the power switching element support plate 9 is mounted.
3 is fastened to the parallel plate portion 91 and the linear projection 92 of the base plate 9. Next, transformer 3,
The full-wave rectification circuit module 4 and the choke coil 7 are attached from above, the full-wave rectification circuit module 4 is fastened, and the core holding plates 31, 71 are fastened. Finally, the terminals of the transformer 3, the full-wave rectifier circuit module 4, and the choke coil 7 are fastened to a bus bar or the like.

The advantages of the DC-DC converter of the present embodiment described above will be described below. Base plate (metal member) 9 that supports and cools the power switching element of the inverter circuit and supports the wiring board
Protects the non-mounting surface of the wiring board at a predetermined interval. Further, the base plate 9 can be supported and cooled by closely adhering to the bottom surface of the transformer 3 or the choke coil 7.

Also, the terminals of the transformer 3 and the choke coil 7, which are taller due to having the core, can be shifted toward the wiring board 8 by the gap between the base plate 9 and the wiring board 8. The connection of other short-circuited components or circuit elements mounted on the transformer 8 to the terminals of the transformer 3 and the choke coil 7 is facilitated. In addition, the transformer 3, the full-wave rectifier circuit module 4, and the choke coil 7 are closely attached to the parallel plate 91 of the base plate 9 through the holes and cutouts of the wiring board 8, so that these components such as the transformer 3 are wired. Compared to the case of providing around the substrate 8, it can be provided at an appropriate place on the wiring, and the space distribution between each component and the wiring can be simplified.
This is also effective for reducing the size of the DC-DC converter device.

Further, the transformer 3 provided on the wiring board 8
Alternatively, the hole or notch for inserting the choke coil 7 can also be used as a guide for positioning the transformer 3 or the choke coil 7.

[0031]

Embodiment 2 Another embodiment will be described with reference to FIG. In this embodiment, the transformer supporting surface 9 of the base plate 9a is
A peripheral wall 9c is provided to surround the bottom of the transformer 3a and cover the bottom of the side surface of the transformer 3a. In this way, the positioning of the transformer 3a can be performed by the base plate 9a, and the cooling performance of the transformer is improved. Note that the transformers 3 and 3a are made of a base plate 9 using an adhesive or grease having excellent heat conductivity.
It is of course possible to adhere to 9a.

[Brief description of the drawings]

FIG. 1 is a circuit diagram showing one embodiment of a DC-DC converter device of the present invention.

FIG. 2 is a perspective view of the DC-DC converter device shown in FIG.

FIG. 3 is a partial perspective view of the DC-DC converter device shown in FIG.

FIG. 4 is an exploded perspective view of the DC-DC converter device shown in FIG.

FIG. 5 is a partial vertical sectional view showing another embodiment of the DC-DC converter device of the present invention.

[Explanation of symbols]

3 is a transformer, 4 is a full-wave rectifier circuit module, 7 is a choke coil, 8 is a wiring board, 9 is a base plate (metal member), 91 is a parallel plate portion of the base plate 9

────────────────────────────────────────────────── ─── Continuation of front page (56) References JP-A-7-143747 (JP, A) JP-A 9-135088 (JP, A) JP-A 8-331865 (JP, A) JP-A-6-331865 351260 (JP, A) JP-A-6-311760 (JP, A) JP-A-5-327249 (JP, A) JP-A-58-3012 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02M 3/28

Claims (8)

(57) [Claims] 1. An input smoothing circuit connected to a DC power supply for smoothing the current, an inverter circuit for converting DC power input from the input smoothing circuit into AC power, and changing an output voltage of the inverter circuit. A DC-DC converter circuit having a transformer, a rectifier circuit for rectifying the output of the transformer, and an output smoothing circuit having a choke coil for smoothing the output voltage of the rectifier circuit; and power switching of the inverter circuit. A metal member on which an element is mounted; and a wiring board on which a circuit element constituting the DC-DC converter circuit is mounted on a mounting surface and fixed to the metal member. A parallel plate portion extending parallel to the anti-mounting surface while facing the anti-mounting surface at a predetermined interval; The bottom surface of the wiring board is provided in close contact with the main surface of the parallel plate portion on the wiring board side, and the transformer or the choke coil is mounted on the mounting surface side of the wiring board from a hole or a cutout provided in the wiring board. And a terminal of the transformer or the choke coil protrudes onto a mounting surface of the wiring board and is connected to a connection terminal on the wiring board side. 2. The DC-DC converter according to claim 1, wherein a terminal of the transformer or the choke coil extends parallel to the mounting surface and is fastened to the connection terminal. DC converter device. 3. The DC-DC converter device according to claim 1, wherein a pair of side plate portions erected from the wiring board along side surfaces of a rectangular core of the transformer or the choke coil, and the both side plate portions. A DC-DC converter device comprising a gate-shaped core pressing plate having a top plate portion provided between the front ends of the rectangular cores and in close contact with the top surface of the rectangular core. 4. The DC-DC converter according to claim 3, wherein a center portion of the top plate portion is curved toward the transformer or the choke coil side to connect the transformer or the choke coil to the parallel plate portion of the base plate. A DC-DC converter device elastically biased toward. 5. The DC-DC converter according to claim 1, wherein the metal member is erected perpendicularly to the parallel plate from one side of the parallel plate toward the wiring board. A DC-DC converter device, comprising: a power switching element supporting plate portion, wherein the power switching element is protruded from the power switching element supporting plate portion toward the wiring board. 6. A DC-DC converter according to claim 4.
At The wiring board is erected from the parallel plate portion and the wiring board is
Fastened to a plurality of wiring board support protrusions on which the board is placed, The both side plate portions of the gate-shaped core holding plate,
The screw hole of the wiring board supporting protrusion penetrating through the hole of the wiring board
Fixed to the wiring board by screws fastened to the
A DC-DC converter device characterized by the above-mentioned. 7. A DC-DC converter according to claim 1.
At The parallel plate portion is provided for the transformer or the choke coil.
A pedestal on which the core is placed, The pedestal part is an end of the transformer or the choke coil.
High enough to allow the child to adhere to the connection terminals on the wiring board.
DC-DC converter device characterized by having
Place. 8. A DC-DC converter according to claim 1.
At The parallel plate portion is provided for the transformer or the choke coil.
DC having a wall portion abutting on a side bottom portion.
A DC converter device.