# US 12,191,777 B2 · Power conversion device

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- Number: US 12,191,777 B2
- Document ID: US12191777B2
- Status: Granted
- Kind: B2
- Application number: 17/749,798
- Filed: 2022-05-20
- Published: 2022-12-01
- Granted: 2025-01-07
- Earliest claimed: 2021-05-31
- Assignees: Hitachi Astemo, Ltd.
- Applicants: Hitachi Astemo, Ltd.
- Inventors: Takayuki Shirai; Takuya Yagi; Shinichiro Hayakawa
- Web page: https://patentgrep.com/patent/US12191777B2

## CPC

- H02M 1/0009: {Devices or circuits for detecting current in a converter}
- H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- G01R 33/07: Hall effect devices
- H02M 3/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- H02M 7/48: using discharge tubes with control electrode or semiconductor devices with control electrode
- H05K 7/14322: {wherein the control and power circuits of a power converter are arranged within the same casing}
- G01R 33/0076: {Protection, e.g. with housings against stray fields}
- G01R 33/072: {Constructional adaptation of the sensor to specific applications}
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- G01R: MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES (indicating correct tuning of resonant circuits H03J3/12)
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS

## Abstract

This power conversion device includes a magnetic core which has a gap formed by cutting out a part of an annular shape, a resin primary molded body configured to hold the magnetic core by covering a first end portion and a second end portion of the magnetic core that are arranged opposite to each other with the gap therebetween from outside of the magnetic core in a radial direction, and a resin secondary molded body which has an exposed portion in which a surface of a portion of the primary molded body that covers the first end portion and the second end portion is exposed, and contains the primary molded body.

## Claims

### Claim 1

A power conversion device comprising:
a magnetic core which has a gap formed by cutting out a part of an annular shape;
a resin primary molded body configured to hold the magnetic core by covering a first end portion and a second end portion of the magnetic core that are arranged opposite to each other with the gap therebetween from outside of the magnetic core in a radial direction; and
a resin secondary molded body which has an exposed portion in which a surface of a portion of the primary molded body that covers the first end portion and the second end portion is exposed, and contains the primary molded body,
wherein the primary molded body has a groove portion in which a first end surface exposed to the gap of the first end portion and a second end surface exposed to the gap of the second end portion are exposed, and
wherein the secondary molded body has a fitting wall portion from an inner wall surface on the first end surface side of the groove portion to an inner wall surface on the second end surface side with the first end surface and the second end surface exposed.

### Claim 2

A power conversion device comprising:
a magnetic core which has a gap formed by cutting out a part of an annular shape;
a resin primary molded body configured to hold the magnetic core by covering a first end portion and a second end portion of the magnetic core that are arranged opposite to each other with the gap therebetween from outside of the magnetic core in a radial direction; and
a resin secondary molded body which has an exposed portion in which a surface of a portion of the primary molded body that covers the first end portion and the second end portion is exposed, and contains the primary molded body,
wherein the primary molded body has a groove portion in which a first end surface exposed to the gap of the first end portion and a second end surface exposed to the gap of the second end portion are exposed, and
wherein the secondary molded body has a claw portion that is locked from the outside of the magnetic core in the radial direction to an inside in the radial direction on a surface of the primary molded body.

### Claim 3

A power conversion device comprising:
a magnetic core which has a gap formed by cutting out a part of an annular shape;
a resin primary molded body configured to hold the magnetic core by covering a first end portion and a second end portion of the magnetic core that are arranged opposite to each other with the gap therebetween from outside of the magnetic core in a radial direction; and
a resin secondary molded body which has an exposed portion in which a surface of a portion of the primary molded body that covers the first end portion and the second end portion is exposed, and contains the primary molded body,
wherein the primary molded body has a groove portion in which a first end surface exposed to the gap of the first end portion and a second end surface exposed to the gap of the second end portion are exposed,
wherein the secondary molded body has a fitting wall portion from an inner wall surface on the first end surface side of the groove portion to an inner wall surface on the second end surface side with the first end surface and the second end surface exposed, and
wherein the secondary molded body has a claw portion that is locked from the outside of the magnetic core in the radial direction to the inside in the radial direction on the surface of the primary molded body.

### Claim 4 (depends on 1)

The power conversion device according to claim 1, further comprising:
a fastening structure in which an end portion of a bus bar inserted into the inside of the magnetic core in the radial direction is fastened,
wherein the fastening structure is held in the primary molded body and arranged adjacent to the magnetic core.

### Claim 5 (depends on 2)

The power conversion device according to claim 2, further comprising:
a fastening structure in which the end portion of the bus bar inserted into the inside of the magnetic core in the radial direction is fastened,
wherein the fastening structure is held in the primary molded body and arranged adjacent to the magnetic core.

### Claim 6 (depends on 3)

The power conversion device according to claim 3, further comprising:
a fastening structure in which the end portion of the bus bar inserted into the inside of the magnetic core in the radial direction is fastened,
wherein the fastening structure is held in the primary molded body and arranged adjacent to the magnetic core.