Electronic circuit board and power conversion device

The present invention relates to an electronic circuit board and power conversion device including a magnetic part that is constructed with the use of a patterned coil of a printed circuit board.

A power conversion device, for example, is constructed from an electronic circuit board and, in some power conversion devices, a surface mounting semiconductor element is mounted on a printed circuit board on which a patterned coil is formed, and a lower surface of the printed circuit board is in contact with a cooler in order to dissipate heat. In addition to the level of cooling performance at which the lower surface of the printed circuit board is cooled, heat interference of the patterned coil and the semiconductor element is an important factor in temperature reduction of the patterned coil and the semiconductor element. As in Patent Literature 1, the heat interference is suppressed by, for example, forming a through-hole in wiring that electrically connects the semiconductor element and the patterned coil, and bringing the through-hole into contact with a cooler for heat radiation.

Patent Literature

[PTL 1] JP 2010-109309 A

Technical Problem

When the area of the printed circuit board is to be reduced, the semiconductor element and the patterned coil, namely, a coil pattern, are positioned closer to each other, which causes heat interference of the semiconductor element and the coil pattern also in portions other than the wiring connecting the semiconductor element and the coil pattern. Heat interference occurs between the semiconductor element and another semiconductor element as well when there are a plurality of semiconductor elements.

It is an object of the present invention to provide an electronic circuit board and a power conversion device, in each of which heat interference is suppressed between mounted parts, for example, a semiconductor element and a magnetic part that is formed by a coiled pattern and by a magnetic core.

Solution to Problem

According to one embodiment of the present invention, there are provided an electronic circuit board and the like including: a multi-layer printed circuit board having mounted thereon a magnetic part and semiconductor elements, the magnetic part being formed by a magnetic core and a coil pattern formed by a circuit pattern, and the semiconductor elements being connected to the circuit pattern; a cooler placed on an opposite side from a mounting surface of the multi-layer printed circuit board; an insulating member, which has heat conductance, and is placed between the multi-layer printed circuit board and the cooler; a screw fixing portion placed in surroundings of the coil pattern and the semiconductor elements to fix the multi-layer printed circuit board and the cooler together; and a heat radiation pattern placed between at least two out of the coil pattern and the semiconductor elements when viewed from a direction perpendicular to a principal surface of the multi-layer printed circuit board, wherein the heat radiation pattern, the screw fixing portion, and the cooler are directly connected in a manner that gives heat conductance and electrical conductance to the heat radiation pattern, the screw fixing portion, and the cooler.

Advantageous Effects of Invention

According to one embodiment of the present invention, it is possible to provide the electronic circuit board and the power conversion device, in each of which heat interference is suppressed between the mounted parts, for example, the semiconductor element and the magnetic part formed by the coiled pattern and the magnetic core.

FIG. 1 is a perspective view of an example of the schematic configuration of a power conversion device according to embodiments of the present invention.

FIG. 2 is a perspective top view of an example of a multi-layer printed circuit board in the power conversion device according to the embodiments of the present invention.

FIG. 3 is an exploded perspective view of portions of magnetic parts that are components of the power conversion device according to the embodiments of the present invention.

FIG. 4 is a circuit diagram of an example of a power conversion device according to a first embodiment of the present invention.

FIGS. 5A to 5D are perspective top views of copper foil patterns on respective layers of a multi-layer printed circuit board of the power conversion device according to the first embodiment of the present invention.

FIGS. 6A to 6D are diagrams for illustrating heat radiation paths of the power conversion device according to the first embodiment of the present invention.

FIG. 7 is a circuit diagram of an example of a power conversion device according to a second embodiment of the present invention.

FIGS. 8A to 8D are perspective top views of copper foil patterns on respective layers of a multi-layer printed circuit board of the power conversion device according to the second embodiment of the present invention.

FIG. 9 is a circuit diagram of an example of a power conversion device according to a third embodiment of the present invention.

FIGS. 10A to 10D are perspective top views of copper foil patterns on respective layers of a multi-layer printed circuit board of the power conversion device according to the third embodiment of the present invention.

FIGS. 11A and 11B are diagrams for illustrating suppression of the warping of the printed circuit board in the third embodiment of the present invention.

FIG. 12 is a diagram for illustrating switching noise blocking in the third embodiment of the present invention.

FIG. 13 is a sectional view of a screw fixing portion in the power conversion device according to the present invention.

FIGS. 14A and 14B are diagrams for illustrating images of heat radiation paths in the power conversion device according to the present invention.

FIG. 15 is a diagram for illustrating a positional relation between the screw fixing portion and a semiconductor element in the third embodiment of the present invention.

FIG. 16 is a diagram for illustrating positional relations of a plurality of semiconductor elements to screw fixing portions around the semiconductor elements in the third embodiment of the present invention.

In the present invention, heat radiation patterns to be connected to screw fixing portions, which are placed around semiconductor elements and a coil pattern, are provided between and around the semiconductor elements and the coil pattern when viewed from a direction perpendicular to the printed circuit board, and the screw fixing portions are connected directly to a cooler in a manner that gives heat conductance and electrical conductance to the screw fixing portions.

Heat transmitted in a planar direction between the plurality of semiconductor elements and the coil pattern is released to the cooler through the heat radiation patterns, and heat interference between mounted parts of the electronic circuit board is consequently suppressed. This allows the mounted parts to be placed close to one another, and helps to reduce the area of the printed circuit board.

The electronic circuit board according to the present invention is described below through embodiments with reference to the drawings, taking as an example a power conversion device in which a transformer is constructed from the coil pattern. In the embodiments, the same or equivalent portions are denoted by the same reference symbols, and a duplicate description is omitted.

First Embodiment

FIG. 1 is a perspective view of an example of the schematic configuration of a power conversion device according to the embodiments of the present invention. The power conversion device includes switching elements 11 and rectifier elements 31 , which are surface mounting semiconductor elements mounted on a front surface of a printed circuit board 8 having a multi-layer structure as described later with reference to FIGS. 5A to 5D and FIGS. 6A to 6D . The power conversion device also includes a patterned coil 81 , a transformer 2 , and a smoothing choke coil 42 . The patterned coil 81 is formed by a coil pattern, which is a circuit pattern on the printed circuit board 8 and which is formed by, for example, a copper foil pattern as described later with reference to FIG. 3 . The transformer 2 and the smoothing choke coil 42 are magnetic parts including magnetic cores ( 23 and 24 ), which form a magnetic path of the patterned coil, and formed from the front surface to a rear surface piercing the printed circuit board 8 . The power conversion device further includes an input capacitor 14 and an output capacitor 41 , which are formed on the front surface of the printed circuit board 8 , and a control circuit 5 , which is described later with reference to FIG. 4 . A cooler 75 , which is high in heat conductance and which absorbs heat generated by the components of the power conversion device, namely, the semiconductor elements ( 11 and 31 ) and the magnetic parts ( 2 and 42 ), is placed on the rear surface of the printed circuit board 8 . The cooler 75 is cooled with air or water to cool the components of the power conversion device. The cooler 75 may be unitary with an exterior case (not shown) of the power conversion device.

FIG. 2 is a perspective top view of an example of the printed circuit board in the power conversion device according to the present invention. As illustrated in FIG. 2 , screw fixing portions 76 are placed around the semiconductor elements ( 11 and 31 ), around the coil pattern corresponding to portions of the magnetic parts ( 2 and 42 ), and in edge portions of the printed circuit board 8 . The printed circuit board 8 is fixed to the cooler 75 at the screw fixing portions 76 with screws 77 . Heat radiation patterns 82 are connected to the screw fixing portions 76 . In FIG. 1 and FIG. 2 and the embodiments described later, elements mounted to the printed circuit board 8 and the layout of the heat radiation pattern slightly vary, but the basic structure is the same.

An insulating sheet 78 , which is an insulating member high in heat conductance and heat radiation effect and electrically insulated, is interposed between the printed circuit board 8 and the cooler 75 as described later with reference to FIGS. 6A to 6D and FIGS. 14A and 14B , in a place between the printed circuit board 8 and the cooler 75 that requires electric insulation.

The principal surfaces of the printed circuit board 8 are given as, for example, a front surface and a rear surface to discriminate the “front surface” and “rear surface” of the printed circuit board 8 from each other. The surface on which the semiconductor elements and others are mounted is the “front surface”.

FIG. 3 is an exploded perspective view of portions of the magnetic parts ( 2 and 42 ) that are components of the power conversion device according to the embodiments of the present invention. The patterned coil 81 is placed around through-holes 84 A, 84 B, and 84 C opened in the printed circuit board 8 . A middle leg portion 23 C and outer leg portions 23 A and 23 B of the E-shaped core 23 are inserted from one surface of the printed circuit board 8 into the through-holes 84 C, 84 A, and 84 B, respectively, so that end surfaces of the leg portions are joined to the I-shaped core 24 , which is on the other surface of the printed circuit board 8 , and so that a magnetic path is formed for a magnetic field generated by the patterned coil 81 . While the cores in the first embodiment have an E shape and an I shape, the cores may be, for example, a combination of an E-shaped core and another E-shaped core, EER-shaped cores in which a section orthogonal to the magnetic path direction of a middle leg portion is circular, a combination of a U-shaped core and an I-shaped core, or a combination of a U-shaped core and another U-shaped core.

FIG. 4 is a circuit diagram of an example of a power conversion device according to the first embodiment of the present invention. A primary-side drive circuit 1 includes switching elements 11 A and 11 B connected in series, and switching elements 11 C and 11 D connected in series. The switching elements are, for example, N-ch MOSFETs. A positive side of the input capacitor 14 , to which an input voltage Vin is supplied, is connected to drain terminals of the switching elements 11 A and 11 C. A negative side of the input capacitor 14 is connected to source terminals of the switching elements 11 B and 11 D. A primary-side winding wire 21 A of the transformer 2 is connected between a connection point 12 , which connects the source side of the switching element 11 A and the drain side of the switching element 11 B, and a connection point 13 , which connects the source side of the switching element 11 C and the drain side of the switching element 11 D. A rectifier circuit 3 includes rectifier elements 31 A and 31 B. The rectifier elements 31 A and 31 B are connected, on the anode side, one end of a secondary-side winding wire 22 A and one end of a secondary-side winding wire 22 B, respectively, in the transformer 2 , and are both connected, on the cathode side, to one end of the smoothing choke coil 42 . The other end of the smoothing choke coil 42 is connected to one end of the output capacitor 41 that is an output of the power conversion device. The other end of the output capacitor 41 , the other end of the secondary-side wiring wire 22 A of the transformer 2 , and the other end of the secondary-side winding wire 22 B of the transformer 2 are each connected to a reference electric potential 71 on the output side of the power conversion device.

In the first embodiment, the primary-side wiring wire 21 A of the transformer 2 is wound in four turns, and the secondary-side winding wires 22 A and 22 B of the transformer 2 are each wound in one turn. A positive voltage and a negative voltage that are each ¼ of the input voltage Vin are accordingly generated in the secondary-side winding wires 22 A and 22 B in a period in which the switching elements 11 A and 11 D are switched on and a period in which the switching elements 11 B and 11 C are turned on. The positive voltage and the negative voltage are rectified by the rectifier elements 31 A and 31 B, and the smoothing choke coil 42 and the output capacitor 41 turn the rectified voltages into a direct-current voltage through smoothing. An output voltage Vo of the power conversion device is determined by the ratio of the number of turns of the primary-side winding wire 21 A and the number of turns of the secondary-side winding wires 22 A and 22 B in the transformer 2 , and the on/off periods of the switching elements 11 A to 11 D.

The control circuit 5 feeds the output voltage Vo between the ends of the output capacitor 41 back to input the output voltage Vo, and is connected to gate terminals of the switching elements 11 A to 11 D. The control circuit 5 controls the on/off periods of the switching elements 11 A to 11 D so that the output voltage Vo reaches a set value determined in advance. While the ratio of the numbers of turns in the transformer 2 is 4:1 in the first embodiment, the ratio of the numbers of turns may be set to 6:1 or 8:1 when the ratio of the input voltage Vin and the output voltage Vo is high, and to 3:1 or 2:1 when the voltage ratio is low.

FIGS. 5A to 5D are perspective top views of copper foil patterns on respective layers of the multi-layer printed circuit board of the power conversion device according to the first embodiment of the present invention. The multi-layer printed circuit board is constructed from a plurality of stacked layers in each of which a heat radiation pattern, a coil pattern, and a circuit pattern are formed on a thin insulating layer as described later with reference to FIGS. 6A to 6D , FIGS. 14A and 14B , and other drawings. FIGS. 5A to 5D , FIGS. 8A to 8D , FIGS. 10A to 10D , and other drawings referred to in a description given later are views seen through the insulating layer, and are each a set of diagrams for illustrating, side by side, the copper foil patterns from which the patterns of the respective layers are formed. FIG. 13 is a sectional view of one screw fixing portion of the power conversion device according to the present invention. The multi-layer printed circuit board 8 has four copper foil layers: a first outer layer, which is illustrated in FIG. 5A and on which surface mounting semiconductor elements and other components are formed, a second outer layer, which is illustrated in FIG. 5D and which is in contact with the cooler 75 directly or via the insulating sheet 78 , and a first inner layer and a second inner layer, which are illustrated in FIG. 5B and FIG. 5C , respectively, and which are sandwiched between the outer layers. The layers are electrically connected by copper plating formed on inner walls of through-holes 86 and holes in the screw fixing portion 76 A to 76 K (the screw fixing portion 76 I does not exist and is skipped). In FIG. 13 , the layers of the printed circuit board 8 are electrically connected by copper plating, which is the heat radiation pattern 82 formed on the inner wall of the screw hole in each of the screen fixing portions 76 A to 76 K and, in this state, the screw 77 reaches into the cooler 75 through a screw hole in the printed circuit board 8 , without running through the insulating sheet 78 , to fix the printed circuit board 8 and the cooler 75 together. When the diameter of the screw fixing portions 76 is too large to plate the inner wall by copper plating, the through-holes 86 are placed in the surroundings of the screw fixing portions 76 . The four copper foil layers are insulated by glass epoxy resin or other types of resin.

As illustrated in FIG. 13 , the ten screw fixing portions 76 A to 76 K arranged along the perimeter of the printed circuit board 8 and fixed to the cooler 75 with screws are in contact with the cooler 75 on the second outer layer of FIG. 5D without running through the insulating sheet 78 , and thus the screw fixing portions 76 A to 76 K has the same electric potential as the reference electric potential 71 on the output side of the power conversion device. An input of the power conversion device is connected to an input portion (Vi) 17 A and an input portion (N) 17 B, which are illustrated in an upper portion of FIG. 5A , and the output of the power conversion device is connected to an output portion (Vo) 18 A, which is illustrated in a lower right portion of FIG. 5A , and the cooler 75 , which has the reference electric potential 71 .

A through-hole 84 C 1 in the printed circuit board 8 is denoted by a reference symbol 84 C 1 in FIG. 5A , and the transformer 2 is constructed from the patterned coil 81 , which is formed by a coil pattern placed around the through-hole 84 C 1 as illustrated in FIG. 3 . In the transformer 2 , the secondary-side winding wire 22 A is placed on the first outer layer of FIG. 5A , the secondary-side winding wire 22 B is placed on the second outer layer of FIG. 5D , and the primary-side winding wire 21 A is placed on the first inner layer of FIG. 5B and the second inner layer of FIG. 5C . The secondary-side winding wires 22 A and 22 B are each wound in one turn, and are connected at one end to the screw fixing portions 76 C and 76 H. The primary-side winding wire 21 A is wound in two turns on each of the first inner layer and the second inner layer, and is connected by the through-holes 86 denoted by the reference symbol 86 of FIG. 5B , and thus the number of turns of the primary-side winding wire 21 A is four turns in total.

Another through-hole 84 C 2 in the printed circuit board 8 is denoted by a reference symbol 84 C 2 in a lower portion of FIG. 5A , and the smoothing choke coil 42 is constructed from the patterned coil 81 placed around the through-hole 84 C 2 as illustrated in FIG. 3 . The smoothing choke coil 42 is wound in one turn on each of the layers illustrated in FIG. 5A to FIG. 5D , and a parallel connection between the first outer layer of FIG. 5A and the first inner layer of FIG. 5B and a parallel connection between the second inner layer of FIG. 5C and the second outer layer of FIG. 5D are connected in series by the through-holes 86 denoted by the reference symbol 86 of FIG. 5B , and thus the number of turns of the smoothing choke coil 42 is two turns in total.

As illustrated in an upper portion of FIG. 5A , the switching elements 11 A to 11 D are arranged between the input portions (Vi) 17 A and (N) 17 B and the transformer 2 in the order of 11 B- 11 A- 11 C- 11 D from the left side of the drawing sheet.

As illustrated in a middle portion of FIG. 5A , the rectifier elements 31 B and 31 A are arranged between the transformer 2 and the smoothing choke coil 42 in the stated order from the left side of the drawing sheet.

Next, a description is given on the positions of the heat radiation patterns 82 , which are high in heat conductance, which are arranged between components, and which are connected to the screw fixing portions 76 A to 76 K having the same electric potential as that of the cooler 75 .

The first outer layer of FIG. 5A includes:

a heat radiation pattern 82 Z 1 connected to the upper left screw fixing portion 76 A and placed between the screw fixing portion 76 A and the input portion 17 B; a heat radiation pattern 82 Z 2 connected to the upper right screw fixing portion 76 K and placed between the screw fixing portion 76 K and the input portion 17 A; heat radiation patterns 82 Z 25 , 82 Z 6 , and 82 Z 7 , to which the left-side screw fixing portions 76 B, 76 C, 76 D, and 76 E are connected; heat radiation patterns 82 Z 3 , 82 Z 4 , and 82 Z 8 , to which the right-side screw fixing portions 76 J, 76 H, 76 G, and 76 F are connected; a heat radiation pattern 82 B, to which the screw fixing portions 76 B and 76 J are connected, and which is placed between the switching elements 11 A and 11 C and the secondary-side winding wire 22 A; a heat radiation pattern 82 Z 5 connected to the screw fixing portion 76 C and placed between the secondary-side winding wire 22 A and the rectifier element 31 B in a manner that makes a part of the heat radiation pattern 82 Z 5 unitary with the secondary-side winding wire 22 A; and a heat radiation pattern 82 D connected to the screw fixing portion 76 F and placed between the smoothing choke coil 42 , the output portion (Vo) 18 A, and the output capacitor (C) 41 .

The first inner layer of FIG. 5B includes:

a heat radiation pattern 82 Z 10 , to which the screw fixing portions 76 B and 76 C of FIG. 5A are connected; a heat radiation pattern 82 Z 9 , to which the screw fixing portions 76 J and 76 H are connected; a heat radiation pattern 82 Z 11 placed between the primary-side winding wire 21 A and the rectifier element 31 B; and a heat radiation pattern 82 F placed between the primary-side winding wire 21 A and the rectifier element 31 A.

The first inner layer of FIG. 5C includes:

a heat radiation pattern 82 Z 12 , to which the screw fixing portions 76 B and 76 C of FIG. 5A are connected; a heat radiation pattern 82 Z 15 , to which the screw fixing portions 76 J and 76 H are connected; a heat radiation pattern 82 Z 13 placed between the primary-side winding wire 21 A and the rectifier element 31 B; and a heat radiation pattern 82 Z 14 placed between the primary-side winding wire 21 A and the rectifier element 31 A.

The second outer layer of FIG. 5D includes:

a heat radiation pattern 82 Z 16 connected to the screw fixing portion 76 A in the upper left portion of FIG. 5A and placed between the screw fixing portion 76 A and the input portion 17 B; a heat radiation pattern 82 Z 17 connected to the screw fixing portion 76 K in the upper right portion of FIG. 5A and placed between the screw fixing portion 76 K and the input portion 17 A; heat radiation patterns 82 Z 19 , 82 Z 21 , and 82 Z 23 , to which the screw fixing portions 76 B, 76 C, 76 D, and 76 E on the left side of FIG. 5A are connected; heat radiation patterns 82 Z 20 , 82 Z 22 , and 82 Z 24 , to which the screw fixing portions 76 J, 76 H, 76 G, and 76 F on the right side of FIG. 5A are connected; a heat radiation pattern 82 C, to which the screw fixing portions 76 B and 76 J are connected, and which is placed between the switching elements 11 A and 11 C and the secondary-side winding wire 22 B; a heat radiation pattern 82 Z 18 connected to the screw fixing portion 76 B and placed between the switching elements 11 A and 11 B; a heat radiation pattern 82 A connected to the screw fixing portion 76 J and placed between the switching elements 11 C and 11 D; a heat radiation pattern 82 G connected to the screw fixing portion 76 H and placed between the secondary-side winding wire 22 B and the rectifier element 31 A in a manner that makes a part of the heat radiation pattern 82 G unitary with the secondary-side winding wire 22 B; a heat radiation pattern 82 E connected to the screw fixing portion 76 F and placed between the smoothing choke coil 42 , the output portion 18 A, and the output capacitor 41 ; and a heat radiation pattern 82 H, to which the screw fixing portions 76 D and 76 G are connected, and which is placed between the rectifier elements 31 A and 31 B and the smoothing choke coil 42 .

In subsequent and other drawings, circuit patterns for electronic circuits electrically connecting parts that are mounted on the printed circuit board 8 , for example, switching elements 11 and rectifier elements 31 , which are semiconductor elements, the transformer 2 and the smoothing choke coil 42 , which are magnetic parts, and the input capacitor 14 and the output capacitor 41 , to one another are omitted because the illustration of the circuit patterns makes the drawings complicate and makes it difficult to see the heat radiation patterns.

Heat radiation paths of the switching elements 11 A to 11 D, the rectifier elements 31 A and 31 B, the primary-side winding wire 21 A and secondary-side winding wires 22 A and 22 B of the transformer 2 , and the patterned coil 81 of the smoothing choke coil 42 are described next with reference to FIGS. 5A to 5D , which are perspective top views of the copper foil patterns, and FIGS. 6A to 6D , which include sectional views of the power conversion device according to the first embodiment. FIG. 6A is a perspective top view of the first outer layer illustrated in FIG. 5A . FIG. 6B to FIG. 6D are sectional views taken along the lines A 1 , A 2 , and A 3 , respectively, in FIG. 6A .

As illustrated in FIG. 6B and FIG. 6D , heat generated by the switching elements 11 A to 11 D and the rectifier elements 31 A and 31 B is transmitted through the through-holes 86 placed in the surroundings of the elements from the first outer layer at the top of the printed circuit board 8 , which is a four-layer substrate, to the second outer layer at the bottom of the four-layer substrate, and is transmitted from the second outer layer to the cooler 75 through the insulating sheet 78 .

As illustrated in FIG. 6C , heat generated by the primary-side winding wire 21 A of the transformer 2 placed on the first inner layer and second inner layer of the printed circuit board 8 is transmitted through the insulating resin of the printed circuit board 8 to the first outer layer and the second outer layer, and is transmitted, along with heat generated by the secondary-side winding wires 22 A and 22 B, which are placed on the first outer layer and the second outer layer, respectively, to the cooler 75 from the screw fixing portions 76 C and 76 H, which are connected to one end of the secondary-side winding wire 22 A and one end of the secondary-side winding wire 22 B as illustrated in FIG. 5A and FIG. 5D . There is also a path along which heat generated by the primary-side winding wire 21 A is transmitted to the through-hole 86 connecting the two turns on the first inner layer and the two turns on the second inner layer, and is transmitted from the second outer layer to the cooler 75 through the insulating sheet 78 .

Heat generated by the patterned coils denoted by the reference symbol 42 of FIG. 5A , FIG. 5B , and FIG. 5C as the smoothing choke coil 42 placed on the first outer layer, the first inner layer, and the second inner layer of the printed circuit board 8 is transmitted to the second outer layer through the insulating resin between the layers of the printed circuit board 8 , and through the through-holes 86 connecting the patterned coils on the layers, and is transmitted, along with heat generated by the patterned coil that is placed on the second outer layer, from the second outer layer to the cooler 75 through the insulating sheet 78 .

Most of the heat generated by the components is transmitted to the cooler 75 through the paths described above. When the components are at a close distance from each other, however, part of heat generated by one component and spread in a planar direction through the insulating resin may be transmitted to another component. The present invention is provided with the heat radiation patterns 82 , which are connected to the screw fixing portions 76 A to 76 K and which have the same electric potential as that of the cooler 75 , in order to suppress heat interference between components. Effects of the heat radiation patterns 82 are described next.

Referring to a section A 1 of FIG. 6B , as illustrated in FIG. 5D , the heat radiation pattern 82 A is placed on the second outer layer between the switching elements 11 C and 11 D, and heat transmitted in a planar direction between the switching elements 11 C and 11 D is transmitted to the heat radiation pattern 82 A. Although some heat may be transmitted between the switching elements 11 C and 11 D in a planar direction of the first outer layer, the first inner layer, and the second inner layer, most of the heat is transmitted to the heat radiation pattern 82 A because the distance between the switching elements 11 C and 11 D and the heat radiation pattern 82 A in a planar direction on the second outer layer is shorter than the distance between the switching elements 11 C and 11 D in a planar direction on the first outer layer, the first inner layer, and the second inner layer.

In addition, heat transmitted to the heat radiation pattern 82 A is readily transmitted to the cooler 75 because the heat radiation pattern 82 A is connected to the screw fixing portion 76 J by the copper foil pattern having a heat conductivity of approximately 400 W/mK, whereas the heat conductivity of the insulating resin is approximately 0.3 W/mK, and also because heat is transmitted from the screw fixing portion 76 J to the cooler 75 without passing through the insulating sheet 78 . Heat interference between the switching elements 11 C and 11 D can be suppressed in this manner.

Referring to the section A 2 of FIG. 6C , heat transmitted in a planar direction between the switching element 11 C and the secondary-side winding wire 22 A on the first outer layer is transmitted to the heat radiation pattern 82 B. Heat transmitted in a planar direction between the switching element 11 C and the secondary-side winding wire 22 B on the second outer layer is transmitted to the heat radiation pattern 82 C.

The thermal resistance on a heat transmission path from the primary-side winding wire 21 A on the first inner layer to a pattern below the switching element 11 C is considered.

When the heat conductivity of the insulating resin is given as “λ”, the distance between the switching element 11 C on the first inner layer and the adjacent primary-side winding wire 21 A in a planar direction is given as “d”, the thickness of each copper foil pattern is given as “t”, a width over which the primary-side winding wire 21 A is in contact with the pattern below the switching element 11 C is given as “w”, and the thermal resistance is represented by “R 1 ”, the thermal resistance is expressed as R 1 =d/(λ× 2 ×t).

The thermal resistance on a heat transmission path from the primary-side winding wire 21 A on the first inner layer to the heat radiation pattern 82 B on the first outer layer is considered.

When the thickness of the insulating resin between the first outer layer and the first inner layer is given as “a”, an area in which the primary-side winding wire 21 A on the first inner layer and the heat radiation pattern 82 B on the first outer layer overlap is given as “s”, and the thermal resistance is represented by “R 2 ”, the thermal resistance is expressed as R 2 =a/(λ×s).

When R 1 and R 2 are set so that R 1 >>R 2 is satisfied, that is, d/(w×t)>>a/s is satisfied, heat generated by the primary-side winding wire 21 A on the first inner layer is transmitted more to the heat radiation pattern 82 B on the first outer layer than in any planar direction. For example, when “d”, “w”, “t”, “a”, and “s” are set to 2 mm, 20 mm, 0.1 mm, 0.2 mm, and 50 mm 2 , respectively, d/(w×t) is calculated as 1 and a/s is calculated as 0.004.

Similarly, heat generated by the primary-side winding wire 21 A on the second inner layer is transmitted more to the heat radiation pattern 82 C on the second outer layer than in any planar direction. Heat transmitted to the heat radiation patterns 82 B and 82 C is transmitted to the cooler 75 from the screw fixing portions 76 B and 76 J. Heat interference between the switching element 11 C and the transformer 2 can be suppressed in this manner.

Referring to the section A 3 of FIG. 6D , the heat radiation patterns 82 D to 82 H are placed between and around the transformer 2 , the rectifier element 31 A, and the smoothing choke coil 42 , and heat interference between the components can be suppressed in the manner described above with reference to the section A 1 and the section A 2 . Heat transmitted from the smoothing choke coil 42 to the output capacitor 41 can also be suppressed by the heat radiation patterns 82 D and 82 E, and the temperature of the output capacitor 41 can accordingly be lowered.

Images of the heat radiation paths described above are described with reference to a sectional view and a top view of FIGS. 14A and 14B . FIGS. 14A and 14B are diagrams for illustrating heat radiation paths in the power conversion device according to the present invention. FIG. 14A is a sectional view, and FIG. 14B is a top view. Arrows H indicate the heat radiation paths. Heat generated by the switching elements 11 , the rectifier elements 31 , and the patterned coil 81 is transmitted mainly to the second outer layer (d), which is the lowermost layer of the printed circuit board 8 , through the through-holes 86 and the insulating layers between the copper foil patterns on the layers of the multi-layer printed circuit board 8 , and is then transmitted to the cooler 75 through the insulating sheet 78 . Part of the heat generated by the switching elements 11 , the rectifier elements 31 , and the patterned coil 81 spreads in a planar direction of the printed circuit board 8 , but is transmitted to the cooler 75 via the heat radiation patterns 82 having heat conductance and the screw fixing portions 76 having heat conductance. This keeps the heat spread in a planar direction from being transmitted to other parts, thereby suppressing heat interference.

While the description given above uses the sections A 1 , A 2 , and A 3 of FIGS. 6A to 6D as an example, the heat radiation patterns 82 formed in other portions have the same effects as well, and are capable of suppressing heat interference between components. Heat transmission to the input capacitor 14 and the control circuit 5 , which is illustrated only in circuit diagrams, can be suppressed in addition to the heat transmission to the output capacitor 41 described above. Parts low in heat resistance temperature can accordingly be used as the input capacitor 14 and the control circuit 5 .

Second Embodiment

A second embodiment of the present invention differs from the first embodiment, which uses a step-down circuit as the step-down transformer 2 of FIG. 4 , in that a step-up circuit is provided.

FIG. 7 is a circuit diagram of an example of a power conversion device according to the second embodiment of the present invention. The step-up transformer 2 of FIG. 7 forms a step-up circuit. The primary-side drive circuit 1 includes switching elements 11 E and 11 F. The switching elements are, for example, P-ch MOSFETs. Drain terminals of the switching elements 11 E and 11 F are connected to one end of a primary-side winding wire 21 B and one end of a primary-side winding wire 21 C in the transformer 2 . The positive side of the input capacitor 14 , to which the input voltage Vin is supplied, is connected to source terminals of the switching elements 11 E and 11 F. The other end of the primary-side winding wire 21 B and the other end of the primary-side winding wire 21 C in the transformer 2 , and the negative side of the input capacitor 14 , are each connected to a reference electric potential 72 on the input side of the power conversion device. The rectifier circuit 3 includes rectifier elements 31 C, 31 D, 31 E, and 31 F. A secondary-side winding wire 22 C of the transformer 2 is connected between a connection point 32 connecting an anode of the rectifier element 31 C and a cathode of the rectifier element 31 D and a connection point 33 connecting an anode of the rectifier element 31 E and a cathode of the rectifier element 31 F. A connection point between a cathode of the rectifier element 31 C and an anode of the rectifier element 31 D is connected to one end of the smoothing choke coil 42 , and the other end of the smoothing choke coil 42 is connected to the positive side of the output capacitor 41 , which is an output of the power conversion device. A connection point between a cathode of the rectifier element 31 E and an anode of the rectifier element 31 F is connected to the negative side of the output capacitor 41 .

In the second embodiment, the primary-side wiring wires 21 B and 21 C of the transformer 2 are each wound in one turn, and the secondary-side winding wire 22 C of the transformer 2 is wound in four turns. A positive voltage and a negative voltage that are each four times the input voltage Vin are accordingly generated in the secondary-side winding wire 22 C in a period in which the switching element 11 E is switched on and a period in which the switching element 11 F is turned on. The positive voltage and the negative voltage are rectified by the rectifier elements 31 C and 31 F, and the smoothing choke coil 42 and the output capacitor 41 turn the rectified voltages into a direct-current voltage through smoothing. An output voltage Vo of the power conversion device is determined by the ratio of the number of turns of the primary-side winding wires 21 B and 21 C and the number of turns of the secondary-side winding wire 22 C in the transformer 2 , and the on/off periods of the switching elements 11 E and 11 F.

The control circuit 5 feeds the output voltage Vo between the ends of the output capacitor 41 back to input the output voltage Vo, and is connected to gate terminals of the switching elements 11 E and 11 F. The control circuit 5 controls the on/off periods of the switching elements 11 E and 11 F so that the output voltage Vo reaches a set value determined in advance. While the ratio of the numbers of turns in the transformer 2 is 1:4 in the second embodiment, the ratio of the numbers of turns may be set to 1:6 or 1:8 when the ratio of the input voltage Vin and the output voltage Vo is high, and to 1:3 or 1:2 when the voltage ratio is low.

FIGS. 8A to 8D are perspective top views of copper foil patterns on respective layers of the multi-layer printed circuit board of the power conversion device according to the second embodiment of the present invention. As in the first embodiment, the multi-layer printed circuit board 8 has four copper foil layers: a first outer layer, which is illustrated in FIG. 8A and on which surface mounting semiconductor elements and other components are formed, a second outer layer, which is illustrated in FIG. 8D and which is in contact with the cooler 75 directly or via the insulating sheet 78 , and a first inner layer and a second inner layer, which are illustrated in FIG. 8B and FIG. 8C , respectively, and which are sandwiched between the outer layers. The layers are electrically connected by copper plating formed on inner walls of through-holes 86 and holes in the screw fixing portion 76 A to 76 K. The detailed configuration thereof is the same as the one described above with reference to FIG. 13 . When the diameter of the screw fixing portions 76 is too large to plate the inner wall by copper plating, the through-holes 86 are placed in the surroundings of the screw fixing portions 76 . The four copper foil layers are insulated by glass epoxy resin or other types of resin.

As illustrated in FIG. 13 , the ten screw fixing portions 76 A to 76 K (the screw fixing portion 76 I does not exist and is skipped) arranged along the perimeter of the printed circuit board 8 and fixed to the cooler 75 with screws are in contact with the cooler 75 on the second outer layer of FIG. 8D without running through the insulating sheet 78 , and thus the screw fixing portions 76 A to 76 K has the same electric potential as the reference electric potential 72 on the input side of the power conversion device. An input of the power conversion device is connected to an input portion (Vi) 17 A, which is illustrated in an upper portion of FIG. 8A , and the cooler 75 , which has the reference electric potential, and the output of the power conversion device is connected to an output portion (Vo) 18 A and an output portion (N) 18 B, which are illustrated in a lower right portion of FIG. 8A .

A through-hole 84 C 1 in the printed circuit board 8 is denoted by a reference symbol 84 C 1 in FIG. 8A , and the transformer 2 is constructed from the patterned coil 81 placed around the through-hole 84 C 1 as illustrated in FIG. 3 . In the transformer 2 , the secondary-side winding wire 21 B is placed on the first outer layer of FIG. 8A , the primary-side winding wire 21 C is placed on the second outer layer of FIG. 8D , and the secondary-side winding wire 22 C is placed on the first inner layer of FIG. 8B and the second inner layer of FIG. 8C . The primary-side winding wires 21 B and 21 C are each wound in one turn, and are connected at one end to the screw fixing portions 76 B and 76 J. The secondary-side winding wire 22 C is wound in two turns on each of the first inner layer and the second inner layer, and is connected by the through-holes 86 denoted by the reference symbol 86 of FIG. 8B , and thus the number of turns of the secondary-side winding wire 22 C is four turns in total.

Another through-hole 84 C 2 in the printed circuit board 8 is denoted by a reference symbol 84 C 2 in a lower portion of FIG. 8A , and the smoothing choke coil 42 is constructed from the patterned coil 81 placed around the through-hole 84 C 2 as illustrated in FIG. 3 . The smoothing choke coil 42 is wound in two turns on each of the layers illustrated in FIG. 8A to FIG. 8D , and are connected by three through-holes 86 denoted by the reference symbol 86 of FIG. 8B , and thus the number of turns of the smoothing choke coil 42 is eight turns in total.

As illustrated in an upper portion of FIG. 8A , the switching elements 11 E and 11 F are arranged between the input portion (Vi) 17 A and the transformer 2 in the order of 11 E and 11 F from the left side of the drawing sheet.

As illustrated in a middle portion of FIG. 8A , the rectifier elements 31 C to 31 F are arranged between the transformer 2 and the smoothing choke coil 42 in the order of 31 D- 31 C- 31 E- 31 F from the left side of the drawing sheet.

Next, a description is given on the positions of the heat radiation patterns 82 , which are arranged between components, and which are connected to the screw fixing portions 76 A to 76 K having the same electric potential as that of the cooler 75 .

The first outer layer of FIG. 8A includes:

a heat radiation pattern 82 Z 32 connected to the upper right screw fixing portion 76 K and placed between the screw fixing portion 76 K and the input portion 17 A; heat radiation patterns 82 Z 31 and 82 Z 35 , to which the screw fixing portions 76 A, 76 B, and 76 C on the upper left side are connected; heat radiation patterns 82 Z 33 and 82 Z 36 , to which the screw fixing portions 76 K, 76 J, and 76 H on the upper right side are connected; a heat radiation pattern 82 Z 38 , to which the screw fixing portions 76 D and 76 E on the lower left side are connected; a heat radiation pattern 82 Z 34 connected to the screw fixing portion 76 J and placed between the primary-side winding wire 21 B and the switching element 11 F in a manner that makes a part of the heat radiation pattern 82 Z 34 unitary with the primary-side winding wire 21 B; a heat radiation pattern 82 Z 37 , to which the screw fixing portions 76 C and 76 H are connected, and which is placed between the rectifier elements 31 C to 31 F and the primary-side winding wire 21 B; and a heat radiation pattern 82 Z 39 connected to the lower right screw fixing portion 76 F and placed between the smoothing choke coil 42 , the output portion 18 A, and the output capacitor (C) 41 .

The second outer layer of FIG. 8D includes:

heat radiation patterns 82 Z 40 and 82 Z 43 , to which the screw fixing portions 76 A, 76 B, and 76 C on the upper left side of FIG. 8A are connected; heat radiation patterns 82 Z 41 and 82 Z 42 , to which the screw fixing portions 76 K, 76 J, and 76 H on the upper right side of FIG. 8A are connected; a heat radiation pattern 82 Z 47 , to which the screw fixing portions 76 D and 76 E on the lower left side of FIG. 8A are connected; a heat radiation pattern 82 Z 49 connected to the screw fixing portion 76 C at the center of the left side of FIG. 8A , and placed between the primary-side winding wire 21 C and the switching element 11 E in a manner that makes a part of the heat radiation pattern 82 Z 49 unitary with the primary-side winding wire 21 C; a heat radiation pattern 82 Z 44 , to which the screw fixing portions 76 C and 76 H at the center of FIG. 8A are connected, and which is placed between the rectifier elements 31 C to 31 F and the primary-side winding wire 21 C, and a heat radiation pattern 82 Z 45 connected to the screw fixing portion 76 C at the center of the left side of FIG. 8A , and placed between the rectifier elements 31 C and 31 D; a heat radiation pattern 82 Z 46 connected to the screw fixing portion 76 H at the center of the right side of FIG. 8A , and placed between the rectifier elements 31 E and 31 F; and a heat radiation pattern 82 Z 48 connected to the screw fixing portion 76 F in the lower right portion of FIG. 8A , and placed between the smoothing choke coil 42 , the output portion 18 A, and the output capacitor 41 .

Main heat radiation paths of the switching elements 11 E and 11 F, the rectifier elements 31 C to 31 F, the transformer 2 , and the smoothing choke coil 42 , and effects of the heat radiation patterns ( 82 ) provided between and around the components, are the same as those in the first embodiment. The second embodiment also has other effects of the first embodiment: the effect of suppressing heat interference among the components and the effect of suppressing heat transmission to the control circuit 5 , which is illustrated only in circuit diagrams.

Third Embodiment

While one transformer 2 is provided in the first embodiment and the second embodiment, a third embodiment of the present invention uses two transformers 2 A and 2 B, in order to deal with high voltage and large current. The transformers in the third embodiment are connected in series on the primary side and connected in parallel on the secondary side to disperse the primary-side voltage and the secondary-side current.

FIG. 9 is a circuit diagram of an example of a power conversion device according to the third embodiment of the present invention. A primary-side drive circuit 1 includes switching elements 11 G and 11 H connected in series, and switching elements 11 J and 11 K connected in series. The switching elements are, for example, N-ch MOSFETs. The positive side of the input capacitor 14 , to which an input voltage Vin is supplied, is connected to drain terminals of the switching elements 11 G and 11 J. Two input capacitors 14 are connected in parallel because the power is larger than in the first embodiment. Source terminals of the switching elements 11 H and 11 K are connected to the negative side of the input capacitors 14 . A primary-side winding wire 21 D of the transformer 2 A and a primary-side winding wire 21 E of the transformer 2 B are connected in series between the connection point 12 , which connects the switching elements 11 G and 11 H, and the connection point 13 , which connects the switching elements 11 J and 11 K. The rectifier circuit 3 includes rectifier elements 31 G, 31 H, 31 J, and 31 K. The rectifier elements 31 G and 31 H are connected, on the anode side, to one end of a secondary-side winding wire 22 D and one end of a secondary-side winding wire 22 E in the transformer 2 A, and are both connected, on the cathode side, to one end of a smoothing choke coil 42 A. The rectifier elements 31 J and 31 K are connected, on the anode side, to one end of a secondary-side winding wire 22 F and one end of a secondary-side winding wire 22 G in the transformer 2 B, and are both connected, on the cathode side, to one end of a smoothing choke coil 42 B. The other end of the smoothing choke coil 42 A and the other end of the smoothing choke coil 42 B are connected to one end of one output capacitor 41 and one end of another output capacitor. The output capacitors 41 are outputs of the power conversion device. The other end of the one output capacitor 41 , the other end of the other output capacitor 41 , the other end of the secondary-side winding wire 22 D and the other end of the secondary-side winding wire 22 E in the transformer 2 A, and the other end of the secondary-side winding wire 22 F and the other end of the secondary-side winding wire 22 G in the transformer 2 B are each connected to the reference electric potential 71 on the output side of the power conversion device. Two output capacitors 41 are connected in parallel because the power is larger than in the first embodiment.

In the third embodiment, the primary-side wiring wires 21 D and 22 E of the transformers 2 A and 2 B are each wound in four turns, and the secondary-side winding wires 22 D, 22 E, 22 F, and 22 G of the transformer 2 are each wound in one turn. A positive voltage and a negative voltage that are each ⅛ of the input voltage Vin are accordingly generated in the secondary-side winding wires 22 D, 22 E, 22 F, and 22 G in a period in which the switching elements 11 G and 11 K are switched on and a period in which the switching elements 11 H and 11 J are turned on. The positive voltage and the negative voltage are rectified by the rectifier elements 31 G, 31 H, 31 J, and 31 K, and the smoothing choke coils 42 A and 42 B and the output capacitor 41 turn the rectified voltages into a direct-current voltage through smoothing. An output voltage Vo of the power conversion device is determined by the ratio of the number of turns of the primary-side winding wire and the number of turns of the secondary-side winding wires in the transformers 2 A and 2 B, and the on/off periods of the switching elements 11 G to 11 K.

The control circuit 5 feeds the output voltage Vo between the ends of the output capacitor 41 back to input the output voltage Vo, and is connected to gate terminals of the switching elements 11 G to 11 K. The control circuit 5 controls the on/off periods of the switching elements 11 G to 11 K so that the output voltage Vo reaches a set value determined in advance. In the third embodiment, in which two transformers 2 A and 2 B are connected in series on the primary side and connected in parallel on the secondary side, the number of turns per transformer can be reduced when the same amount of step down, that is, to ⅛ of the input voltage, is to be performed, and the wiring width of the patterned coil 81 illustrated in FIG. 3 can accordingly be widened. In addition, the parallel connection of the transformers 2 A and 2 B on the secondary side and the parallel connection of the smoothing choke coils 42 A and 42 B allow the secondary-side current to be dispersed, which enables the power conversion device to deal with high voltage and large current.

FIGS. 10A to 10D are perspective top views of copper foil patterns on respective layers of the multi-layer printed circuit board of the power conversion device according to the third embodiment of the present invention. As in the first embodiment, the multi-layer printed circuit board 8 has four copper foil layers: a first outer layer, which is illustrated in FIG. 10A and on which surface mounting semiconductor elements and other components are formed, a second outer layer, which is illustrated in FIG. 10D and which is in contact with the cooler 75 directly or via the insulating sheet 78 , and a first inner layer and a second inner layer, which are illustrated in FIG. 10B and FIG. 10C , respectively, and which are sandwiched between the outer layers. The layers are electrically connected by copper plating formed on inner walls of through-holes 86 and holes in the screw fixing portion 76 A to 76 M (the screw fixing portion 76 I does not exist and is skipped). The detailed configuration thereof is the same as the one described above with reference to FIG. 13 . When the diameter of the screw fixing portions 76 is too large to plate the inner wall by copper plating, the through-holes 86 are placed in the surroundings of the screw fixing portions 76 . The four copper foil layers are insulated by glass epoxy resin or other types of resin.

As illustrated in FIG. 13 , the twelve screw fixing portions 76 A to 76 M arranged along the perimeter and at the center of the printed circuit board 8 and fixed to the cooler 75 with screws are in contact with the cooler 75 on the second outer layer of FIG. 10D without running through the insulating sheet 78 , and thus the screw fixing portions 76 A to 76 M has the same electric potential as the reference electric potential 71 on the output side of the power conversion device. An input of the power conversion device is connected to an input portion (Vi) 17 A and an input portion (N) 17 B, which are illustrated in an upper portion of FIG. 10A , and the output of the power conversion device is connected to an output portion (Vo) 18 A, which is illustrated in the center of a lower portion of FIG. 10A , and the cooler 75 , which has the reference electric potential.

A through-hole 84 C 3 in the printed circuit board 8 is denoted by a reference symbol 84 C 3 in FIG. 10A , and the transformer 2 A is constructed from the patterned coil 81 placed around the through-hole 84 C 1 as illustrated in FIG. 3 . In the transformer 2 A, the secondary-side winding wire 22 D is placed on the first outer layer of FIG. 10A , the secondary-side winding wire 22 E is placed on the second outer layer of FIG. 10D , and the primary-side winding wire 21 D is placed on the first inner layer of FIG. 10B and the second inner layer of FIG. 10C . A through-hole 84 C 4 in the printed circuit board 8 is denoted by a reference symbol 84 C 4 in FIG. 10A , and the transformer 2 B is constructed from the patterned coil 81 placed around the through-hole 84 C 4 as illustrated in FIG. 3 . In the transformer 2 B, the secondary-side winding wire 22 F is placed on the first outer layer of FIG. 10A , the secondary-side winding wire 22 G is placed on the second outer layer of FIG. 10D , and the primary-side winding wire 21 E is placed on the first inner layer of FIG. 10B and the second inner layer of FIG. 10C . The secondary-side winding wires 22 D to 22 G are each wound in one turn, and are connected at one end to the screw fixing portions 76 B, 76 D, 76 H, and 76 K at the center of the printed circuit board 8 in FIG. 10A . The primary-side winding wires 21 D and 21 E are each wound in two turns on each of the first inner layer and the second inner layer. The two turns on the first inner layer and the two turns on the second inner layer are connected by the through-holes 86 denoted by the reference symbol 86 of FIG. 10B , and thus the number of turns of each primary-side winding wire is four turns in total. The primary-side winding wire 21 D wound in four turns and the primary-side winding wire 21 E wound in four turns are connected in series, which brings the total number of turns to eight.

Another through-hole 84 C 5 in the printed circuit board 8 is denoted by a reference symbol 84 C 5 in a lower left portion of FIG. 10A , and the smoothing choke coil 42 A is constructed from the patterned coil 81 placed around the through-hole 84 C 5 as illustrated in FIG. 3 . The smoothing choke coil 42 B is similarly constructed around a through-hole 84 C 6 denoted by a reference symbol 84 C 6 in a lower right portion of FIG. 10A . The smoothing choke coils 42 A and 42 B are each wound in one turn on each layer. A parallel connection between one turn on the first outer layer of FIG. 10A and one turn on the first inner layer of FIG. 10B and a parallel connection between one turn on the second inner layer of FIG. 10C and one turn on the second outer layer of FIG. 10D are connected by the through-holes 86 of FIG. 10B , and thus the number of turns of each smoothing choke coil 42 is two turns in total.

As illustrated in an upper portion of FIG. 10A , the switching elements 11 G to 11 K are arranged between the input portions 17 A and 17 B and the transformers 2 A and 2 B in the order of 11 H- 11 G- 11 J- 11 K from the left side of the drawing sheet.

As illustrated in a middle portion of FIG. 10A , the rectifier elements 31 G to 31 K are arranged so that the rectifier elements 31 H and 31 G are placed to the left of the transformer 2 A in the stated order from the upper end of the drawing sheet, and so that the rectifier elements 31 K and 31 J are placed to the right of the transformer 2 B in the stated order from the upper end of the sheet of paper.

Next, a description is given on the positions of the heat radiation patterns 82 , which are arranged between components, and which are connected to the screw fixing portions 76 A to 76 M having the same electric potential as that of the cooler 75 .

The first outer layer of FIG. 10A includes:

a heat radiation pattern 82 Z 51 connected to a screw fixing portion 76 M at the center of an upper portion and placed on the upper left side, on which the screw fixing portion 76 A is located, and a heat radiation pattern 82 Z 52 connected to the screw fixing portion 76 M and placed on the upper right side, on which a screw fixing portion 76 L is located; a heat radiation pattern 82 Z 53 , to which the screw fixing portions 76 A and 76 C on the upper left side are connected, and a heat radiation pattern 82 Z 82 , to which the screw fixing portions 76 A and 76 C and the screw fixing portion 76 B are connected; a heat radiation pattern 82 Z 54 connected to the screw fixing portion 76 C at the center of the left side, and placed on the lower left side, on which the screw fixing portion 76 E is located; a heat radiation pattern 82 Z 61 , to which the screw fixing portion 76 L and a screw fixing portion 76 J on the upper right side are connected, and a heat radiation pattern 82 Z 60 , to which the screw fixing portions 76 L and 76 J and the screw fixing portion 76 K are connected; a heat radiation pattern 82 Z 59 connected to the screw fixing portion 76 J at the center of the right side, and placed on the lower right side, on which the screw fixing portion 76 G is located; a heat radiation pattern 82 Z 55 connected to the lower left screw fixing portion 76 D, and placed between the smoothing choke coil 42 A, an output portion 18 A, and the output capacitors 41 ; a heat radiation pattern 82 Z 58 connected to the lower right screw fixing portion 76 H, and placed between the smoothing choke coil 42 B, the output portion 18 A, and the output capacitors 41 ; and a heat radiation pattern 82 Z 56 connected to the screw fixing portion 76 F at the center of a lower portion and placed between the smoothing choke coil 42 A and the output capacitors 41 , and a heat radiation pattern 82 Z 57 connected to the screw fixing portion 76 F and placed between the smoothing choke coil 42 B and the output capacitors 41 .

The second outer layer of FIG. 10D includes:

a heat radiation pattern 82 Z 63 connected to the screw fixing portion 76 M at the center of the upper portion of FIG. 10A and placed on the left side, on which the screw fixing portion 76 A is located, and a heat radiation pattern 82 Z 64 connected to the screw fixing portion 76 M and placed on the right side, on which the screw fixing portion 76 L is located; a heat radiation pattern 82 Z 62 connected to the screw fixing portion 76 B on the left side of FIG. 10A , and placed between the switching elements 11 G and 11 H; a heat radiation pattern 82 Z 65 connected to the screw fixing portion 76 K on the right side of FIG. 10A , and placed between the switching elements 11 J and 11 K; a heat radiation pattern 82 Z 81 to which the screw fixing portions 76 A and 76 C on the left side of FIG. 10A are connected, and a heat radiation pattern 82 Z 80 to which the screw fixing portions 76 A and 76 C and the screw fixing portion 76 B are connected; a heat radiation pattern 82 Z 77 connected to the screw fixing portion 76 C at the center of the left side of FIG. 10A , and placed on the lower left side, on which the screw fixing portion 76 E is located; a heat radiation pattern 82 Z 66 to which the screw fixing portions 76 L and 76 J on the right side of FIG. 10A are connected, and a heat radiation pattern 82 Z 67 to which the screw fixing portions 76 L and 76 J and the screw fixing portion 76 K are connected; a heat radiation pattern 82 Z 70 connected to the screw fixing portion 76 J at the center of the right portion of FIG. 10A , and placed on the lower right side, on which the screw fixing portion 76 G is located; a heat radiation pattern 82 Z 79 connected to the screw fixing portion 76 B on the left side of FIG. 10A , and placed between the secondary-side winding wire 22 E and the rectifier element 31 H; a heat radiation pattern 82 Z 68 connected to the screw fixing portion 76 K on the right side of FIG. 10A , and placed between the secondary-side winding wire 22 G and the rectifier element 31 K; a heat radiation pattern 82 Z 76 connected to the screw fixing portion 76 D on the left side of FIG. 10A , and placed between the secondary-side winding wire 22 E and the rectifier element 31 G; a heat radiation pattern 82 Z 71 connected to the screw fixing portion 76 H on the right side of FIG. 10A , and placed between the secondary-side winding wire 22 G and the rectifier element 31 J; a heat radiation pattern 82 Z 75 connected to the screw fixing portion 76 D on the left side of FIG. 10A , and placed between the smoothing choke coil 42 A, the output portion 18 A, and the output capacitors 41 ; a heat radiation pattern 82 Z 72 connected to the screw fixing portion 76 H on the right side of FIG. 10A , and placed between the smoothing choke coil 42 B, the output portion 18 A, and the output capacitors 41 ; and a heat radiation pattern 82 Z 74 connected to the screw fixing portion 76 F at the center of the lower portion of FIG. 10A and placed between the smoothing choke coil 42 A and the output capacitors 41 , and a heat radiation pattern 82 Z 73 connected to the screw fixing portion 76 F and placed between the smoothing choke coil 42 B and the output capacitors 41 .

Main heat radiation paths of the switching elements 11 G to 11 K, the rectifier elements 31 G to 31 K, the transformers 2 A and 2 B, and the smoothing choke coils 42 A and 42 B, and effects of the heat radiation patterns ( 82 ) provided between and around the components, are the same as those in the first embodiment. The third embodiment also has other effects of the first embodiment: the effect of suppressing heat interference among the components and the effect of suppressing heat transmission to the control circuit 5 , which is illustrated only in circuit diagrams.

In the third embodiment, the transformers 2 A and 2 B are placed at the center of the printed circuit board 8 , the switching elements 11 G to 11 K and the rectifier elements 31 G to 31 K are placed around the transformers 2 A and 2 B, the screw fixing portions 76 A to 76 M placed around the transformers 2 A and 2 B at the center of the printed circuit board 8 double as electric connection of the reference electric potential at one end of the secondary-side winding wires 22 D to 22 G, and as heat conduction connection from the heat radiation patterns 82 , and the screw fixing portions 76 are arranged along the perimeter of the printed circuit board 8 for the dual purpose of fixing the circuit board and connecting heat conduction from the heat radiation patterns 82 . Heat interference between components can thus be suppressed without increasing the number of screw fixing points when the number of components is increased in order to deal with high voltage and large current.

As illustrated in FIG. 11A , when the printed circuit board 8 is fixed while squashing the soft insulating sheet 78 interposed between the printed circuit board 8 and the cooler 75 , the insulating sheet 78 is not flattened thoroughly if the screw fixing portions 76 are situated far from the switching elements 11 and the rectifier elements 31 , with the result that the insulating sheet 78 remains thick in places right below the switching elements 11 and the rectifier elements 31 , which may deteriorate heat radiation performance. FIG. 15 is a diagram for illustrating the characteristics of a positional relation of the screw fixing portions 76 to the switching elements 11 or the rectifier elements 31 in the third embodiment. In the third embodiment, each switching element 11 or each rectifier element 31 is placed on a line segment connecting the centers of two screw fixing portions 76 that are placed in the vicinity of the switching element 11 or the rectifier element 31 as illustrated in, for example, FIGS. 10A to 10D and FIG. 15 . This ensures that the insulating sheet 78 is flattened evenly as illustrated in FIG. 11B , and prevents the insulating sheet 78 from remaining thick in places. The heat radiation performance for heat generated by the switching elements 11 , the rectifier elements 31 , and other components is consequently prevented from deteriorating. When the printed circuit board 8 has a thickness of from 1.0 mm to 2.0 mm, the distance between the centers of two screw fixing portions 76 , which are placed in the vicinity of one switching element 11 or one rectifier element 31 , is, for example, from about 10 mm to about 30 mm. The insulating sheet 78 is flattened more evenly and the heat radiation performance deteriorates less when the switching element 11 or the rectifier element 31 is placed closer to the midpoint of the line segment connecting the centers of the two screw fixing portions 76 .

As illustrated in FIG. 12 , the switching elements 11 and the rectifier elements 31 are switched in the range of from several ten kHz to several hundred kHz, and there is a possibility that high frequency noise is superimposed on the output of the power conversion device. In the third embodiment, however, the core 23 of the transformers 2 A and 2 B and of the smoothing choke coils 42 A and 42 B is placed between the switching elements 11 , the rectifier elements 31 , the output capacitors 41 , and the output portion 18 A, and is capable of blocking high frequency noise propagated in the air and transmitted to the output capacitors 41 and the output portion 18 A.

The present invention is not limited to each of the above-mentioned embodiments, and includes all possible combinations of those embodiments.

As described above, the present invention is not limited to a power conversion device, and is also applicable to various electronic circuit boards having a configuration similar to that of a power conversion device in which a magnetic part including a coil pattern and a magnetic core and a semiconductor element are mounted on a printed circuit board, and the printed circuit board is fixed to a cooler by a screw fixing portion.

The electronic circuit board according to the present invention in the description given above includes: a multi-layer printed circuit board ( 8 ), on which magnetic parts ( FIG. 3 ) and semiconductor elements ( 11 and 31 ) are mounted, the magnetic parts being formed by a coil pattern ( 81 ) formed by magnetic cores ( 23 and 24 ) and circuit patterns, the semiconductor elements being connected to the circuit patterns; a cooler ( 75 ) placed on an opposite side from a mounting surface of the multi-layer printed circuit board; an insulating member ( 78 ), which has heat conductance, and is placed between the multi-layer printed circuit board and the cooler; screw fixing portions ( 76 ) placed in surroundings of the coil pattern ( 81 ) and the semiconductor elements ( 11 and 31 ) to fix the multi-layer printed circuit board ( 8 ) and the cooler ( 75 ) together; and heat radiation patterns ( 82 ) placed between at least two out of the coil pattern ( 81 ) and the semiconductor elements ( 11 and 31 ) when viewed from a direction perpendicular to a principal surface of the multi-layer printed circuit board ( 8 ). The heat radiation patterns ( 82 : FIGS. 5A to 5D and other drawings), the screw fixing portions ( 76 ), and the cooler ( 75 ) are directly connected in a manner that gives heat conductance and electrical conductance to the heat radiation patterns ( 82 ), the screw fixing portions ( 76 ), and the cooler ( 75 ).

With the configuration described above, heat transmitted in a planar direction between the plurality of semiconductor elements ( 11 and 31 ) and the coil pattern ( 81 ) is released to the cooler ( 75 ) through the heat radiation patterns ( 82 ), and heat interference between components of the electronic circuit board or components of a power conversion device can accordingly be suppressed. This allows the components to be placed close to one another and enables the multi-layer printed circuit board to have a small area.

In the electronic circuit board according to the present invention, the heat radiation patterns ( 82 ) are placed also in surroundings of at least one of the coil pattern ( 81 ) and the semiconductor elements ( 11 and 31 ) when viewed from the direction perpendicular to the principal surface of the multi-layer printed circuit board ( 8 ).

This configuration has, in addition to the effect of suppressing heat interference between the plurality of semiconductor elements ( 11 and 31 ) and the coil pattern ( 81 ), an effect in that heat transmitted from the plurality of semiconductor elements ( 11 and 31 ) and the coil pattern ( 81 ) in a planar direction is prevented from being transmitted to other mounted parts that are components of the power conversion device, for example, an input capacitor ( 14 ), an output capacitor ( 41 ), and a control circuit ( 5 ). Consequently, parts low in heat resistance can be used as the other mounted parts.

In the electronic circuit board according to the present invention, the heat radiation patterns ( 82 ) are placed so that the heat radiation patterns ( 82 ) overlap with the coil pattern ( 81 ), or with the circuit pattern electrically connecting mounted parts to one another, when viewed from the direction perpendicular to the principal surface of the multi-layer printed circuit board ( 8 ).

With this configuration, the distance between the plurality of semiconductor elements ( 11 and 31 ) and the coil pattern ( 81 ) can be made closer even though the heat radiation patterns ( 82 ) are placed between and around the plurality of semiconductor elements ( 11 and 31 ) and the coil pattern ( 81 ), because the coil pattern ( 81 ), the heat radiation patterns ( 82 ), and the circuit patterns connecting the mounted parts to one another are placed so that the patterns overlap with one another.

In the electronic circuit board according to the present invention, a primary-side winding wire ( 21 ) and a secondary-side winding wire ( 22 ) of a transformer ( 2 ), which is a magnetic part, are constructed from the coil pattern ( 81 ) placed so as to overlap when viewed from the direction perpendicular to the principal surface of the multi-layer printed circuit board ( 8 ), and one end of one of the primary-side winding wire ( 21 ) and the secondary-side winding wire ( 22 ) that has a smaller number of turns is connected to the screw fixing portions ( 76 ), and is electrically connected to the cooler ( 75 ).

With this configuration, one end of the coil pattern ( 81 ) is thermally connected to the cooler ( 75 ), and the heat radiation performance for heat from the coil pattern ( 81 ) is accordingly improved. This configuration also keeps the number of screw fixing portions ( 76 ) from increasing because the same screw fixing portions ( 76 ) are shared as the screw fixing portions ( 76 ) to which the heat radiation patterns ( 82 ) are connected and as the screw fixing portions ( 76 ) to which the one end of the coil pattern ( 81 ) is connected.

In the electronic circuit board according to the present invention, one end of the coil pattern ( 81 ) is connected to the screw fixing portions ( 76 ).

With this configuration, the screw fixing portions ( 76 ) to which the one end of the coil pattern ( 81 ) is connected are used also as the screw fixing portions ( 76 ) to which the heat radiation patterns ( 82 ) are connected, which means that one screw fixing portion ( 76 ) can be shared between different uses.

A power conversion device according to the present invention is constructed from the electronic circuit board described above, includes, as magnetic parts, a step-up transformer ( 2 : FIG. 7 ) or a step-down transformer ( 2 : FIG. 4 ) and a smoothing choke coil ( 42 ), and includes, as semiconductor elements ( 11 and 31 ), switching elements ( 11 ) connected to a primary side of the step-up transformer ( 2 : FIG. 7 ) or the step-down transformer ( 2 : FIG. 4 ) and rectifier elements ( 31 ) connected to a secondary side of the step-up transformer ( 2 : FIG. 7 ) or the step-down transformer ( 2 : FIG. 4 ). The switching elements ( 11 ), the step-up transformer ( 2 : FIG. 7 ) or the step-down transformer ( 2 : FIG. 4 ), the rectifier elements ( 31 ), and the smoothing choke coil ( 42 ) are placed on the multi-layer printed circuit board ( 8 ) in the stated order.

With this configuration, the screw fixing portions ( 76 ) and the heat radiation patterns ( 82 ) are easily placed and shared, and can accordingly be reduced in number.

A power conversion device according to the present invention is constructed from the electronic circuit board described above, includes, as magnetic parts, two step-down transformers ( 2 A and 2 B) and two smoothing choke coils ( 42 A and 42 B), and includes, as semiconductor elements ( 11 and 31 ), a plurality of switching elements ( 11 ) connected to a primary side of the two step-down transformers ( 2 A and 2 B) and rectifier elements ( 31 ) connected to a secondary side of the two step-down transformers ( 2 A and 2 B). Primary-side winding wires ( 21 D and 21 E) of the two step-down transformers ( 2 A and 2 B) are connected in series, and a secondary-side circuit formed by secondary-side winding wires ( 22 ), the rectifier elements ( 31 G to 31 K), and the smoothing choke coils ( 42 A and 42 B) is connected in parallel. As illustrated in FIG. 16 , the two step-down transformers ( 2 A and 2 B) are placed at the center when viewed from a direction perpendicular to the principal surface of the multi-layer printed circuit board ( 8 ), and the plurality of switching elements ( 11 ), the rectifier elements ( 31 ), and the smoothing choke coils ( 42 ) are placed around the two step-down transformers ( 2 A and 2 B). The plurality of switching elements ( 11 ) and the rectifier elements ( 31 ) are arranged in a U shape. The screw fixing portions ( 76 ) are arranged into a triangular lattice pattern around the two step-down transformers ( 2 A and 2 B) and around the plurality of switching elements ( 11 ), the rectifier elements ( 31 ), and the smoothing choke coils ( 42 ).

With this configuration, two or more screw fixing portions ( 76 ) are placed around the semiconductor elements ( 11 and 31 ) and around the coil pattern ( 81 ) each, and the warping of the circuit board is accordingly suppressed, thereby avoiding the deterioration of heat radiation performance due to the warping of the circuit board. In addition, with the smoothing choke coils ( 42 ) placed between the semiconductor elements ( 11 and 31 ), which are sources of noise, and another circuit, which receives the noise, the cores ( 23 and 24 ) of the smoothing choke coils ( 42 ) suppresses noise radiated to the other circuit.

In the electronic circuit board according to the present invention, the semiconductor elements ( 11 and 31 ) are each placed on a line segment connecting the centers of two screw fixing portions ( 76 ). This suppresses the warping of the printed circuit board in the portions of the semiconductor elements ( 11 and 31 ), and enables the electronic circuit board to dissipate heat efficiently even when the semiconductor elements ( 11 and 31 ) are of the type that generates a large amount of heat.

Step-down transformers ( 2 A and 2 B), the smoothing choke coils ( 42 ), the semiconductor elements ( 11 and 31 ), and the screw fixing portions ( 76 ) are arranged on the printed circuit board ( 8 ) as described above with reference to FIG. 16 . The same screw fixing portion ( 76 ) is shared as the screw fixing portion ( 76 ) that is a reference for a line segment with which the placement and position of one semiconductor element are determined, and as the screw fixing portion ( 76 ) that is a reference for a line segment with which the placement and position of another semiconductor element is determined. In other words, the plurality of semiconductor elements ( 11 and 31 ) are placed so that one screw fixing portions ( 76 ) is used as a reference for line segments with which the placement and positions of a plurality of semiconductor elements ( 11 and 31 ) are determined. The number of screw fixing portions ( 76 ) can be reduced in this manner.

1 primary-side drive circuit; 2 , 2 A, 2 B transformer; 3 rectifier circuit; 5 control circuit; 8 printed circuit board; 11 , 11 A to 11 K switching element; 12 , 13 connection point; 14 input capacitor; 17 A, 17 B input portion; 18 A, 118 B output portion; 21 A to 21 E primary-side winding wire; 22 A to 22 G secondary-side winding wire; 23 E-shaped core; 23 A, 23 B outer leg portion; 23 C middle leg portion; 24 I-shaped core; 31 , 31 A to 31 K rectifier element; 32 , 33 connection point; 41 output capacitor; 42 , 42 A, 42 B smoothing choke coil; 71 , 72 reference electric potential; 75 cooler; 76 , 76 A to 76 M screw fixing portion; 78 insulating sheet; 81 patterned coil; 82 heat radiation pattern; 84 A to 84 C through-hole; 86 through-hole; H arrow