IP Library › Granted Patent US 10,625,609
Granted Patent B2
US 10,625,609 · App. 15/115,051 · Granted Apr 21, 2020

Power control unit

Inventor: Osamu Kitazawa (Okazaki, JP)
Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
B60L11/1811B60L50/14B60L50/40B60L53/20B60W10/08B60W20/00H02K11/33H02M3/04H02M3/155H02M7/537H02M7/5387H02P27/06B60L2210/10B60L2210/40H02M2001/007Y10S903/906
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Quick Facts
Patent No.
US 10,625,609
App. No.
15/115,051
Granted
Apr 21, 2020
Kind
B2
Abstract

In a power control unit provided in this application, a reactor ( 38 ) and a DC/DC converter (step-down transformer) ( 24 ) are stacked, and a capacitor ( 40 ) is arranged next to these. The capacitor ( 40 ) is fixed at fixing points (a cradle ( 90 ) and a fixing protrusion ( 88 )) in two locations, and is also fixed to the DC/DC converter ( 24 ) by a bus bar ( 104 ) that electrically connects a terminal ( 78 ) of the capacitor to a terminal ( 100 ) of the DC/DC converter. A fixing position by the bus bar ( 104 ) is a position away from a straight line that passes through the fixing points in two locations, which is advantageous for suppressing vibrations around this straight line.

Claims (41)

1. A power control unit that converts direct-current power to alternating-current power and supplies the converted power to an electric motor for driving a vehicle, the power control unit being fixed inside of an onboard device case, the power control unit comprising:

a step-down transformer configured to step down voltage of the direct-current power; and

a step-up transformer configured to step up voltage of the direct-current power, the step-up transformer including a reactor and a capacitor,

the reactor and the step-down transformer being fixed to the onboard device case, and the reactor and the step-down transformer being vertically arranged,

the capacitor being arranged next to at least one of the reactor or the step-down transformer, with respect to a direction in which the reactor and the step-down transformer are vertically arranged, and

the capacitor and at least one of the step-down transformer or the reactor are configured to be fixed together by a bus bar so as to reduce vibrations due to varying magnetic field generated from a ripple current, the bus bar being configured to electrically connect a terminal of the capacitor to a terminal of at least one of the step-down transformer or the reactor,

wherein the capacitor is fixed to the onboard device case at fixing points in two locations, and the bus bar fixes the capacitor to at least one of the step-down transformer or the reactor at a position away from a straight line that passes through the fixing points in two locations in a vertical direction, and

wherein the bus bar extends in a direction that intersects a direction in which the straight line that passes through the fixing points in two locations of the capacitor extends, and the bus bar is a linear shaped flat plate-like conductor plate.

2. The power control unit according to claim 1 , wherein

a position where the capacitor is fixed by the bus bar is on a side opposite a side where the fixing points are positioned, in the vertical direction.

3. The power control unit according to claim 1 , wherein

the capacitor is fixed to the onboard device case at fixing points in three or more locations; and

the onboard device case includes a partition wall that divides a space inside the onboard device case, an opening is provided in the partition wall, the capacitor passes through the opening, and at least one of the step-down transformer or the reactor is fixed to the partition wall.

4. The power control unit according to claim 3 , wherein

the step-down transformer and the reactor are fixed to a front and a back, respectively, of the partition wall.

5. The power control unit according to claim 1 , wherein

the bus bar fixes at least one of the step-down transformer or the reactor to the capacitor, and the step-down transformer and the reactor are fixed to a partition wall.

6. The power control unit according to claim 5 , wherein

the step-down transformer and the reactor are fixed to a front and a back, respectively, of the partition wall.

7. The power control unit according to claim 1 , wherein

the terminal of the capacitor and the terminal of the step-down transformer each include a positive terminal and a negative terminal; and

the bus bar includes a positive bus bar and a negative bus bar, the bus bar connects the capacitor to the step-down transformer, the positive bus bar connects the positive terminals together, and the negative bus bar connects the negative terminals together.

8. The power control unit according to claim 1 , wherein

the capacitor includes a capacitor element, the capacitor element includes two electrode plates, an insulation member is arranged between the two electrode plates, and the two electrode plates are rolled into a roll shape, and

a surface of the capacitor element is arranged facing the step-down transformer and the reactor, and the surface of the capacitor element is parallel to an axis of the roll of the electrode plates.

9. The power control unit according to claim 8 , wherein

a wire extending from the capacitor element to the terminal of the capacitor is arranged obliquely at an angle with respect to the axis of the roll of the electrode plates.

10. The power control unit according to claim 1 , wherein

the capacitor includes a capacitor element, the capacitor element includes two electrode plates, an insulation member is arranged between the two electrode plates, and the two electrode plates are rolled into a roll shape, and

a surface of the capacitor element is orthogonal to an axis of the roll of the electrode plates.

11. The power control unit according to claim 10 , wherein

a wire extending from the capacitor element to the terminal of the capacitor is arranged obliquely at an angle with respect to the axis of the roll of the electrode plates.

12. The power control unit according to claim 1 , wherein a cooler is sandwiched between the step-down transformer and the reactor.

13. The power control unit according to claim 1 , wherein the capacitor is included in a capacitor case, at least one fixing protrusion extending from at least one surface of the capacitor case, and

wherein the onboard device case further comprises at least one cradle configured to be fixed to the at least one fixing protrusion by a fastening element.

14. A power control unit that converts direct-current power to alternating-current power and supplies the converted power to an electric motor for driving a vehicle, the power control unit being fixed inside of an onboard device case, the power control unit comprising:

a step-down transformer configured to step down voltage of the direct-current power; and

a step-up transformer configured to step up voltage of the direct-current power, the step-up transformer including a reactor and a capacitor,

the reactor and the step-down transformer being fixed to the onboard device case, and the reactor and the step-down transformer being vertically arranged,

the capacitor being arranged next to at least one of the reactor or the step-down transformer, and

the capacitor and at least one of the step-down transformer or the reactor are configured to be fixed together by at least one bus bar so as to reduce vibrations due to varying magnetic field generated from a ripple current, the at least one bus bar being configured to electrically connect at least one terminal of the capacitor to at least one terminal of at least one of the step-down transformer or the reactor.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 1, 2020
From: TOYOTA JIDOSHA KABUSHIKI KAISHA
To: DENSO CORPORATION
Reel/Frame 052279/0846 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 28, 2016
From: KITAZAWA, OSAMU
To: TOYOTA JIDOSHA KABUSHIKI KAISHA
Reel/Frame 039502/0778 →
Priority Claims (1)
JP 2014-016960 · Jan 31, 2014 · national
Continuity (1)
Related Publication 20160347190A1 · Dec 1, 2016