DE102013203498A1 - Power converter e.g. multi-phase converter, comprises a circuit carrier having a busbar, on which the electronic circuit portions are arranged - Google Patents

Abstract

The invention relates to a power converter (30) comprising a first circuit carrier (36) in which a high-current region is implemented, and a second circuit carrier (41) in which a logic part is implemented, wherein the first circuit carrier (4, 36) a bus bar (6, 38), on which electronic circuit parts are arranged.

Description

The invention relates to a power converter.

State of the art

A power converter, which may also be referred to as a DC-DC converter or DC / DC converter, is designed to convert a DC voltage at the input into a DC voltage with a different voltage level. Such a power converter can also be designed as a multi-phase converter.

One from the publication DE 10 2010 062 240 A1 known multiphase converter comprises a plurality of electrical phases, which are each controlled by switching means, wherein at least one coupling means is provided which magnetically couples at least one first phase with at least one further phase, wherein at least two phases to be coupled are at least partially enclosed by the coupling means, wherein at least an insulating body is provided which receives the phases to be coupled and on which at least one fastening means is provided, which cooperates for fastening with at least one of the phases.

A similar multi-phase converter is in the document WO 2012/028558 A1 described.

Disclosure of the invention

Against this background, a power converter with the features of claim 1 is presented. Further embodiments of the invention will become apparent from the dependent claims and the description.

A mechanic concept for the construction of the power converter is proposed, which can also be referred to as a power conversion unit (PCU) and meets specific requirements with regard to conversion performance, efficiency and installation space. For this purpose, the power converter may have at least two circuit carriers and a coupling device for the phases of the power converter, wherein this coupling device has a plurality of coupling modules, which are designed in the form of ferrite cores. The presented power converter can also be designed as a multi-phase converter.

In the described power converter, a first circuit carrier for a high-current range comprises electronic circuit parts which are arranged on a switching rail designed as a thick copper printed circuit board, which can also be referred to as a bus-bar printed circuit board. The first circuit carrier may be formed as a so-called power board and / or have a reinforced copper inner layer, whereby an increased current carrying capacity and improved cooling of the circuit parts can be achieved. In addition, the first circuit carrier may have as electronic circuit parts unpackaged power modules, which may be connected directly to a leadframe and thus to a chip housing, which can be completely encapsulated and thus packaged during manufacturing according to a transfermold process. Thus, the high power losses of the power modules can be optimally cooled. In addition, due to the high current carrying capacity of the leadframe low power dissipation.

A second circuit carrier for a logic part comprises further electronic circuit parts, for example logic modules, which are arranged on a standard printed circuit board, for example with the material identifier FR4, which usually comprises a glass fiber mat impregnated in epoxy resin. This second circuit carrier may be formed as a so-called logic board and compared to the first circuit carrier have a thinner, standardized copper inner layer. Thus, the first circuit carrier has a thicker copper layer thickness than the second circuit carrier. However, it is alternatively or additionally also possible to associate with the first circuit carrier at least one electronic circuit part designed as a logic module.

In one embodiment, the coupling device may have, for example, nine ferrite cores as well as high current and logic connections as interfaces. The number of coupling modules is usually adapted to the number of phases.

Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings.

It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination indicated, but also in other combinations or in isolation, without departing from the scope of the present invention.

Brief description of the drawings

1 shows a schematic representation of a first embodiment of the power converter and individual components of the power converter from different perspectives.

2 shows a schematic representation of details of a second embodiment of the power converter.

Embodiments of the invention

The invention is schematically illustrated by means of embodiments in the drawings and will be described in detail below with reference to the drawings.

The figures are described in a coherent and comprehensive manner, like reference numerals designate like components.

A first embodiment of the power converter 2 is in 1a shown schematically. 1b shows a schematic representation of a first circuit carrier 4 , for a high current range of the power converter 2 comprising at least one half-bridge and at least one polarity reversal protection module, which here on a busbar 6 are arranged, which can also be designed as a printed circuit board with thick copper circuit board or bus bar circuit board, and at least one layer of copper, here, for example, six layers of copper, each having a thickness of about 105 microns.

A coupling device 8th for phases of the power converter 2 is in 1c shown schematically and includes here nine coupling modules 10 , which are formed as ferrite cores. Conductor loops for transporting the flowing phases of the power converter 2 are through these coupling modules 10 guided and thus of the coupling modules 10 at least partially enclosed. By this measure, an electromagnetic compatibility of the power converter 2 be improved. The coupling modules 10 the coupling device 8th are here on a rack 12 arranged. 1c also shows connection modules 14 for the conductor loops of the phases.

Furthermore, the coupling device 8th an interface module 16 with a high current connection 18 and logic connections 20 assigned to the power converter 2 is to be connected to other devices via such connections, which form internal and external interfaces.

The first circuit carrier 4 on the busbar 6 , the coupling device 8th as well as the interface module 16 are in a housing of the power converter 2 arranged as the first housing shell 22 a lid and as a second housing shell 24 a container having a bottom and a side wall, at the bottom cooling modules 25 are arranged. The power converter shown here 2 has a volume of here, for example, about 1500 cm ³ .

An in 2 schematically illustrated second embodiment of the power converter 30 includes a housing with a first housing shell 32 , which is designed here as a lid, and a second housing shell 34 , which is designed here as a container. In an assembled state, the two housing shells enclose 32 . 34 the components of the power converter described below 30 ,

Here is the first housing shell 32 formed of layered metal. Such a layer metal may be produced as a sheet metal or from die-cast aluminum. The second housing shell 34 made of aluminum includes a bottom and an outer wall and can be manufactured in a die-casting process. In addition, in and / or at the bottom of the housing shell 34 a cooling module 35 for active and / or passive cooling of the components of the power converter 30 arranged.

The individual components of the power converter 30 are arranged one above the other. As components, the power converter includes 30 in detail a first circuit carrier 36 for a high current area, which is a busbar 38 and thus comprises a printed circuit printed circuit board of six layers with a thickness of 105 microns and arranged thereon electronic circuit parts. Continue to be on the busbar 38 three press fits (press fit) as connecting elements 40 arranged over which the first circuit carrier 36 with a second circuit carrier 41 for a logic part, which consequently is on the first circuit carrier 36 is arranged.

The second circuit carrier 41 for the logic part includes a conventional circuit board 42 , which is formed from an impregnated in epoxy glass fiber mat and can also be referred to as FR4 circuit board. On the circuit board 42 of the second circuit carrier 41 are electronic circuit parts as logical components of the second circuit substrate 41 and at least one multiple connector strip 44 arranged over which the second circuit carrier 41 with a coupling device arranged above it 46 for inductive coupling of phases of the power converter 30 to connect.

This coupling device 46 comprises several, in this embodiment, nine, ferrite cores as coupling modules 48 , through the conductor loops for the phases of the power converter 30 are guided, wherein the coupling modules 48 are interconnected by the conductor loops. Consequently, the conductor loops designed as plastic-coated and / or coated wires are at least in sections of the coupling modules 48 enclosed. The coupling device 46 Here at least one logic module is assigned, which is in and / or on the coupling device 46 is arranged, and has at least one interface for power transmission. The logic module is here with the first circuit carrier 36 connected for the high current area. During operation of the power converter 30 phases flow through the conductor loops. In this case, the magnetic fields induced by the phases are mutually and / or by the coupling modules 48 compensated.

The coupling modules 48 are here in a plastic frame and thus integrated. In addition, the coupling modules 48 interconnected by bonds and can with the first housing shell 32 be connected via at least one thermally conductive separating element. The coupling device 46 is also an interface module 50 with a high current connection 52 and logic connections 54 assigned.

Overall, both feature featured power converters 2 . 30 a first circuit carrier 4 . 36 , in which a high current range is implemented, and a second circuit carrier 41 in which a logic part is implemented on. In this case, the first circuit carrier comprises 4 . 36 a busbar 6 . 38 , are arranged on the electronic circuit parts.

In design are on the busbar 6 . 38 as connecting elements 40 Press seats arranged. In addition, the busbar 6 . 38 be designed as a thick copper circuit board.

The second circuit carrier 41 every power converter 2 . 30 comprises a printed circuit board on which electronic circuit parts are arranged.

In addition, each embodiment of the power converter 2 . 30 a coupling device 8th . 46 with several coupling modules 10 . 48 with openings on, through the conductor loops for phases of the power converter 2 . 30 are guided. In this case, the coupling modules 10 . 48 be designed as ferrite cores. Furthermore, the coupling device 8th . 46 at least one interface module 16 assigned.

The housing of each power converter 2 . 30 has at least two housing shells 22 . 24 . 32 . 34 on, wherein at least one housing shell 22 . 24 . 32 . 34 at least one cooling module 25 . 35 assigned. In addition, the coupling device 8th . 46 in one of these housing shells 22 . 24 . 32 . 34 encapsulated and from this housing shell 22 . 24 . 32 . 34 be thermally connected via a thermally conductive separating element.

The two circuit carriers 4 . 36 . 41 and the coupling device 8th . 46 are interconnected. Inside the housing is the second circuit carrier 41 , in which the logic part of the power converter 2 . 30 is implemented between the first circuit carrier 4 . 36 , in which the high-current range of the power converter 2 . 30 is implemented, and the coupling device 8th . 46 arranged.

It may alternatively or additionally be provided that at least one coupling module 10 . 48 , Usually designed as a ferrite core ferrite module, for dissipation of the resulting heat dissipation in the ferrite core via a heat conducting material to the at least one housing shell 22 . 24 is connected. The presented power converter 2 . 30 can be realized in design via a so-called power circuit board with integrated logic devices, so that no separate logic board is required.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102010062240 A1 [0003]
• WO 2012/028558 A1 [0004]

Claims (9)

Power converter having a first circuit carrier ( 4 . 36 ), in which a high current range is implemented, and a second circuit carrier ( 41 ) in which a logic part is implemented, wherein the first circuit carrier ( 4 . 36 ) a busbar ( 6 . 38 ), are arranged on the electronic circuit parts. Power converter according to claim 1, wherein on the busbar ( 6 . 38 ) Press seats as connecting elements ( 40 ) are arranged. Power converter according to Claim 1 or 2, in which the busbar ( 6 . 38 ) is designed as a thick copper circuit board. Power converter according to one of the preceding claims, in which the second circuit carrier ( 41 ) a printed circuit board ( 42 ), are arranged on the electronic circuit parts. Power converter according to one of the preceding claims, comprising a coupling device ( 8th . 46 ) with several coupling modules ( 10 . 48 ) through the conductor loops for phases of the power converter ( 2 . 30 ) are guided. Power converter according to Claim 5, in which the coupling modules ( 10 . 48 ) are formed as ferrite cores Power converter according to Claim 4 or 5, in which the coupling device ( 8th . 46 ) at least one interface module ( 16 ) assigned. Power converter according to one of the preceding claims, comprising a housing, the at least two housing shells ( 22 . 24 . 32 . 34 ). Power converter according to claim 8, wherein at least one housing shell ( 22 . 24 . 32 . 34 ) at least one cooling module ( 25 . 35 ) assigned.

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