Inverter capacitor system with internal cooling channels

Abstract

The present disclosure provides an "inverter capacitor system with internal cooling channels". An inverter system control (ISC) module is provided. The ISC module includes: a power module that defines a coolant channel for receiving coolant; and a capacitor assembly disposed adjacent to the power module. The capacitor assembly includes a housing, a potting material disposed within the housing, and a plurality of power supplies disposed within the potting material. The capacitor assembly further includes a cooling bar that extends between the power supplies within the potting material and further extends out of the potting material and into the power module.

Description

Technical Field

[0001] The present disclosure generally relates to hybrid electric vehicles having an inverter system controller module as part of their powertrain, and more particularly to systems and methods for cooling an inverter system controller module. Background Art

[0002] Hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), fuel cell vehicles, and other known electrified vehicles differ from conventional motor vehicles in that they are powered by one or more electric motors instead of or in addition to an internal combustion engine (i.e., electric motors and / or generators). High voltage current is typically supplied to the electric motors by one or more batteries that store electrical power.

[0003] Several types of electric / hybrid powertrains include an inverter system controller module (ISCM) that converts high voltage DC power stored in a battery into high voltage AC power used by an electric / hybrid transmission's electric motor. Generally, the heat generated by the ISCM increases as the power output of the device increases. Therefore, thermal management of the heat generated by the ISCM components may be required. Summary of the Invention

[0004] In at least one method, an inverter system is provided. The inverter system may include a power module that defines a coolant passage for receiving coolant. The inverter system may further include a capacitor assembly disposed adjacent to the power module. The capacitor assembly may include a housing, a potting material disposed within the housing, and a plurality of power supplies disposed within the potting material. The inverter system may further include cooling bars that extend between the power supplies within the potting material and further extend out of the potting material and into the power module. The capacitor assembly may include (N-2) / 2 cooling bars, where N is the number of power supplies disposed within the potting material.

[0005] In at least one method, the cooling bar may define a hollow tube that extends through a wall of the power module and into the coolant passage of the power module.

[0006] In at least another method, the cooling bar may be a multi-component cooling bar that includes a tube that extends within the potting material and defines a tube tip that extends out of the potting material, and a coolant tip that is fixed to the tube tip. The coolant tip may extend through a wall of the power module and into the coolant passage of the power module.

[0007] In at least one method, a cooling bar can extend through a wall of a power module and into a coolant channel of the power module. The cooling bar can define a tip portion disposed within the coolant channel, and the tip portion can define a plurality of spaced-apart elongate fins. The tip portion can define an array of at least four spaced-apart elongate fins.

[0008] At least a portion of the cooling bar can extend within a potting material and define a hollow tube having a first cavity. In at least one method, the tip portion can define a hollow tip portion having a second cavity that is in fluid communication with the first cavity. In at least another method, the tip portion can be a substantially solid tip portion without an internal cavity.

[0009] In at least one method, an inverter system control module can include a power module adapted to receive coolant and a capacitor assembly adjacent to the power module. The capacitor assembly can include capacitor cells disposed within the potting material and the cooling bar. The cooling bar can include a first and a second tip that extend through a wall of the power module and define a first and a second opening. The cooling bar can further include a hollow body that extends between the first tip and the second tip and at least partially extends within the potting material.

[0010] The first tip can be a coolant receiving tip, and the second tip can be a coolant discharge tip disposed downstream of an intended coolant flow path. The first and second openings of the first and second tips can be adapted to permit fluid communication between the coolant channel of the power module and the hollow body.

[0011] The hollow body can define an inlet tube portion having a first central axis, an intermediate tube portion having a second central axis that is angularly offset from the first central axis, and an outlet tube portion having a third central axis that is angularly displaced from the second central axis and is substantially parallel to the first central axis.

[0012] The inlet tube portion and the outlet tube portion can be disposed in contact with the potting material. The intermediate tube portion can be not in contact with the potting material.

[0013] The cooling bar can be a multi-discrete component cooling bar. The first tip can be rigidly fixed to the inlet tube portion, and the second tip can be rigidly fixed to the outlet tube portion.

[0014] In at least one method, an electrified vehicle includes: a DC power source configured to provide power to an electric drive system of the vehicle; and an inverter system control (ISC) circuit coupled to the power source and configured to receive DC power from the power source. The ISC circuit can include: a power module that defines a coolant passage for receiving a coolant; and a capacitor assembly disposed adjacent to the power module. The capacitor assembly can include a housing, a potting material disposed within the housing, a plurality of power sources disposed within the potting material, and a cooling bar extending between the power sources within the potting material and further extending out of the potting material and into the power module.

[0015] The potting material can include a thermally conductive electrical insulating material. The power sources can include capacitor units. The capacitor assembly can include at least one of an input capacitor and a DC link capacitor. The cooling bar can be a multi-component cooling bar that includes a tube extending within the potting material and defining a tip extending out of the potting material, and a coolant tip fixed to the tip of the tube. The coolant tip can extend through a wall of the power module and into the coolant passage of the power module.

[0016] The cooling bar can extend through a wall of the power module and into the coolant passage of the power module. The cooling bar can define a tip portion disposed within the coolant passage. The tip portion can define a plurality of spaced-apart elongated fins. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematically shows a powertrain of an electrified vehicle.

[0018] Figure 2 Schematically shows an exemplary battery control system.

[0019] Figure 3 is a perspective view of an exemplary inverter system controller module.

[0020] Figure 4 is a perspective view of an exemplary capacitor assembly.

[0021] Figure 5 is Figure 4 a side elevation sectional view of the capacitor assembly of

[0022] Figure 6 is a side elevation sectional view of another capacitor assembly.

[0023] Figure 7 is Figure 6 an enlarged view of the cooling bar of

[0024] Figure 8 is a side elevation sectional view of yet another capacitor assembly.

[0025] Figure 9It is a side elevation cross-sectional view of yet another capacitor assembly.

[0026] Figure 10 It is an enlarged view of an alternative cooling bar.

[0027] Figure 11 It is a side elevation cross-sectional view of yet another capacitor assembly.

[0028] Figure 12 It is Figure 11 a side perspective cross-sectional view of the capacitor assembly of

[0029] Figure 13 It is a side elevation cross-sectional view of yet another capacitor assembly. Detailed Description

[0030] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take various forms and alternative forms. The drawings are not necessarily to scale; some features may be enlarged or minimized to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one skilled in the art to employ the present invention in different ways. As will be understood by one of ordinary skill in the art, the various features shown and described with reference to any one of the drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. Combinations of the features shown provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for a particular application or implementation.

[0031] Figure 1 A powertrain 10 for an electrified vehicle 12, such as an HEV, is schematically shown. Although described as an HEV, it should be understood that the concepts described herein are not limited to HEVs and may extend to other electrified vehicles, including but not limited to PHEVs, BEVs, and fuel cell vehicles.

[0032] In one method, the powertrain 10 is a power split system that may employ a first drive system including a combination of an engine 14 and a generator 16 (i.e., a first electric machine) and a second drive system including at least one motor 36 (i.e., a second electric machine), the generator 16, and a power source pack 50. For example, the motor 36, the generator 16, and the power source pack 50 may constitute an electric drive system 25 of the powertrain 10. The first and second drive systems may generate torque to drive one or more sets of vehicle drive wheels 30 of the electrified vehicle 12.

[0033] An engine 14, such as an internal combustion engine, and a generator 16 can be connected by a power transmission unit 18. In one non-limiting approach, the power transmission unit 18 is a planetary gear set. Of course, other types of power transmission units, including other gear sets and transmissions, can be used to connect the engine 14 to the generator 16. The power transmission unit 18 can include a ring gear 20, a sun gear 22, and a carrier assembly 24. When used as a generator, the generator 16 can be driven by the power transmission unit 18 to convert kinetic energy into electrical energy. The generator 16 can alternatively be used as a motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft 26 that is connected to the carrier assembly 24 of the power transmission unit 18. Since the generator 16 can be operably connected to the engine 14, the speed of the engine 14 can be controlled by the generator 16.

[0034] The ring gear 20 of the power transmission unit 18 can be connected to a shaft 28, and the shaft 28 is connected to vehicle drive wheels 30 through a second power transmission unit 32. The second power transmission unit 32 can include a gear set having a plurality of gears 34A, 34B, 34C, 34D, 34E, and 34F. Other power transmission units can also be suitable. The gears 34A-34F can transmit torque from the engine 14 to a differential 38 to provide traction to the vehicle drive wheels 30. The differential 38 can include a plurality of gears that enable torque to be transmitted to the vehicle drive wheels 30. The second power transmission unit 32 can be mechanically coupled to a shaft 40 through the differential 38 to distribute torque to the vehicle drive wheels 30.

[0035] A motor 36 can also be used to drive the vehicle drive wheels 30 by outputting torque to a shaft 46, which is also connected to the second power transmission unit 32. In one embodiment, the motor 36 and the generator 16 can be part of a regenerative braking system, where both the motor 36 and the generator 16 can be used as motors to output torque. For example, both the motor 36 and the generator 16 can output power to a high-voltage bus 48 and a power pack 50. The power pack 50 can be a high-voltage battery that is capable of outputting power to operate the motor 36 and the generator 16. Other types of energy storage devices and / or output devices can also be incorporated for use with the electrified vehicle 12.

[0036] The motor 36, the generator 16, the power transmission unit 18, and the power transmission unit 32 can generally be referred to as a transaxle 42 or a transmission of the electrified vehicle 12. Thus, when a driver selects a specific shift position, the transaxle 42 can be appropriately controlled to provide a corresponding gear for propelling the electrified vehicle 12 by providing traction to the vehicle drive wheels 30.

[0037] The powertrain 10 may additionally include a control system 44 for monitoring and / or controlling various aspects of the electrified vehicle 12. For example, the control system 44 may communicate with the electric drive system 25, the power transfer units 18, 32, or other components to monitor and / or control the electrified vehicle 12. The control system 44 may include electronics and / or software to perform the necessary control functions for operating the electrified vehicle 12. In one approach, the control system 44 may be a combination of a vehicle system controller and a powertrain control module (VSC / PCM). Although shown as a single hardware device, the control system 44 may include multiple controllers in the form of multiple hardware devices, or multiple software controllers within one or more hardware devices.

[0038] A controller area network (CAN) 52 may allow the control system 44 to communicate with the transaxle 42. For example, the control system 44 may receive signals from the transaxle 42 to indicate whether a shift position transition is occurring. The control system 44 may also communicate with a battery control module or other control device of the power pack 50.

[0039] Additionally, the electric drive system 25 may include one or more controllers 54, such as an inverter system controller (ISC). The controller 54 may be configured to control specific components within the transaxle 42, such as the generator 16 and / or the motor 36, such as to support bidirectional power flow. In one embodiment, the controller 54 is an inverter system controller combined with a variable voltage converter (ISC / VVC).

[0040] Figure 2 An exemplary battery control system 60 is shown. The battery control system 60 may include a power pack 50, an inverter system controller (ISC) 62, a motor 36, a transmission 64, and an engine 14. The battery control system 60 may additionally be in electrical communication with an external energy source 66.

[0041] The power pack 50 may include one or more power sources 71 and contactors 70. The contactors 70 may be selectively opened / closed to disconnect / connect the power source 71 of the power pack 50 from the high voltage bus 72. For example, the contactors 70 may be selectively closed to apply DC voltage from the power pack 50 to the high voltage bus 72, and the contactors 70 may be selectively opened to disconnect the power pack 50 from the high voltage bus 72. In at least one approach, the contactors 70 may be controlled by a control module (not shown), such as a battery energy control module (BECM). In at least one approach, a high voltage cable 78 may connect the power pack 50 to the ISC 62.

[0042] In at least one method, the ISC 62 can be an inverter system controller combined with a variable voltage converter. The ISC 62 can include a plurality of switching devices 74 for controlling the bi-directional power flow within the battery control system 60. In at least one method, the switching device 74 can be an insulated gate bipolar transistor (IGBT). The switching device 74 can be selectively commanded to switch to convert the DC voltage from the power pack 50 into a three-phase AC voltage to power the motor 36 (i.e., propel the vehicle), or alternatively, to convert the three-phase AC voltage into a DC voltage to electrically recharge the power source 71 of the power pack 50.

[0043] The transmission 64 can include a gear system required to utilize the power from the motor 36 to start the engine 14 during vehicle start-up conditions. The transmission 64 can also transfer power from the engine 14 to the motor 36 to recharge the power pack 50 regeneratively.

[0044] The external energy source 66 can be a component separate from the electrified vehicle. In at least one method, the external energy source 66 can be a lead-acid battery charger. In at least another method, the external energy source 66 can be a low-voltage battery. Other external energy sources are also within the scope of the present disclosure.

[0045] Now referring Figure 3 , the inverter system controller (ISC) module 80 can include a housing 82. In at least one method, the housing 82 can be fixed to the bottom plate 84 to define a cavity therebetween. In at least another method, the housing 82 can be fixed to another vehicle component (such as a transmission housing) to define a cavity therebetween.

[0046] The ISC module 80 can also include a control board 90 and a gate drive board 92. In at least one method, the board 90 can be formed separately. In at least another method, the boards 90, 92 can be formed as a single unit.

[0047] In at least one method, the ISC module 80 can also include an inductor 94. In at least another method, such as in many BEV implementations, the ISC module 80 can not include an inductor 94.

[0048] The ISC module 80 can also include a discharge resistor 96. In at least one method, the discharge resistor 96 can include a molded busbar assembly. In at least another method, the molded busbar assembly can be provided separately. The ISC module 80 can also include a current sensor 98.

[0049] The ISC module 80 can also be a capacitor assembly 100. The capacitor assembly 100 can be an input capacitor, a DC link capacitor, or a combination of an input capacitor and a DC link capacitor. In yet another approach, the ISC module 80 can include multiple capacitor assemblies 100. In this way, the first capacitor assembly can be an input capacitor, and the second capacitor assembly can be a DC link capacitor. In one example, a dual ISC (such as in a PHEV / FHEV vehicle) can include a VVC inductor and can include both an input capacitor and a DC link capacitor. In another example, a vehicle (such as a BEV vehicle) can be provided with a DC link capacitor and the VVC inductor can be omitted.

[0050] The input capacitor assembly 100 can be disposed near the power module 102. The power module 102 can include a first opening 104 and a second opening 106. The power module 102 can define one or more internal cavities, such as a supply chamber 108 and a return chamber 110. Chambers 108, 110 can be adapted to allow coolant to pass therethrough. In this way, chambers 108, 110 can be referred to as coolant channels. Chambers 108, 110 can be located on opposite sides of a separator. In Figure 3 the method shown, the supply chamber 108 and the return chamber 110 are positioned side by side; however, other configurations can be envisioned. The supply chamber 108 can include a port connected to a supply line, and the return chamber 110 can include a port connected to a return line. The supply line and the return line can form part of a larger thermal management system that can include pumps, radiators, other lines, valves, and other components.

[0051] During operation, pressurized coolant can be provided to the supply chamber 108 to cool the power module 102. The coolant can pass through the return chamber 110 to exit the power module 102. The separator can help ensure that the coolant flows through the power module 102 before exiting through the return chamber 110.

[0052] Now referring to Figure 4 , the capacitor assembly 100 can include a housing 120 that defines a top surface 122, which can define the top plane of the capacitor assembly 100. The capacitor assembly 100 can also include one or more power sources 124. In at least one method, the power source 124 can be a capacitor unit and can form a capacitor bank within the housing 120. The capacitor unit can be any suitable type, such as a supercapacitor, an ultracapacitor, an electrochemical capacitor, or an electric double layer capacitor.

[0053] In at least one method, the power source 124 can be another power source, such as a battery having multiple electrical interconnect units or fuel cells. If a battery is used, it can be any suitable type, such as nickel-metal hydride (Ni-MH), nickel-iron (Ni-Fe), nickel-cadmium (Ni-Cd), lead-acid, zinc bromide (Zn-Br), or lithium-based. In at least one method, the battery can be used in combination with one or more capacitors.

[0054] The housing 120 can be filled with a potting material 126. The potting material 126 can be a thermally conductive electrical insulating material, such as an epoxy resin, resin, or adhesive. The potting material 126 can fix and protect the power source 124. Alternatively, the potting material 126 can be the housing 120.

[0055] In some methods, high temperatures can cause capacitors to break down at lower voltage levels. High temperatures may also have an adverse effect on the electrical performance of the capacitors and shorten their service life.

[0056] In this way, the input capacitor assembly 100 can be provided with at least one cooling bar 130. The cooling bar 130 can be a thermally conductive material, such as metal. The cooling bar 130 can extend within the potting material 126 and between the power sources 124. The cooling bar 130 can also extend out of the potting material 126 and can extend above the top surface 122 of the housing 120. The number of cooling bars 130 can be selected according to the number of power sources 124. For example, the capacitor assembly 100 can be provided with (N - 2) / 2 cooling bars 130, where N is an even value representing the number of power sources 124 disposed within the potting material 126. In Figure 4 the method shown, the capacitor assembly 100 is provided with 2 cooling bars 130 and 6 power sources 124.

[0057] Figure 5 as can be seen, the cooling bar 130 extends within the potting material 126 and extends out of the potting material and above the top surface 122 of the housing 120. In at least one method, the cooling bar 130 can extend through the wall 132 of the power module and into the coolant channel 134 of the power module 102 (which can correspond to Figure 3 the supply chamber 108 shown in

[0058] In Figure 5In the method shown, the cooling bar 130 defines a hollow tube that defines an internal cavity. The cooling bar 130 extends upward from the inductor assembly 100, passes through the wall 132 of the power module 102, and enters the coolant channel 134 of the power module 102. In this way, the coolant flowing through the coolant channel 134 (as shown by arrow 140) can cool the coolant tip 136 of the cooling bar 130. Thus, the cooling bar 130 can effect heat transfer between the potting material 126 and the coolant passing through the coolant channel 134 (as shown by arrow 142).

[0059] Although shown in Figure 5 as a hollow tube defining an internal cavity, in another method, the cooling bar 130 can be a solid cooling bar without an internal cavity.

[0060] Referring to Figure 6 , in yet another method, the cooling bar 150 can be a multi-component cooling bar. The cooling bar 150 can include a tube portion 152 that extends within the potting material 126 and defines a tube tip 154 that extends out of the potting material 126. The cooling bar 150 can also include a coolant tip 156 that is fixed to the tube tip 154. The coolant tip 156 can extend through the wall 132 of the power module 102 and into the coolant channel 134 of the power module 102.

[0061] The coolant tip 156 can be fixed to the tube tip 154 in any suitable manner. In at least one method, the coolant tip 156 can be fixed to the tube tip 154 by interference fit (e.g., press fit, snap fit) engagement. In another method, the tube tip 154 and the coolant tip 156 can be provided with complementary threaded regions to allow threaded engagement between the tube tip 154 and the coolant tip 156.

[0062] The coolant tip 156 can similarly be fixed to the wall 132 of the power module 102 by interference fit (e.g., press fit, snap fit) engagement. In another method, the wall 132 (e.g., at the hole in the wall 132) and the coolant tip 156 can be provided with complementary threaded regions to allow threaded engagement between the wall 132 and the coolant tip 156.

[0063] Referring to Figure 7 , the coolant tip 156 can include a bulbous region 158 disposed on a first side of the wall 132 and a protruding region 160 disposed on a second side of the wall 132. The bulbous region 158 can be provided with an inner diameter sized to be greater than the outer diameter of the tube tip 154. In this way, the coolant tip 156 can be received within the bulbous region 158. In yet another method, the coolant tip 156 can be sized to be received within the inner diameter of the tube tip 154.

[0064] In at least one method, a seal 162 can be disposed between the coolant tip 156 and the tube portion 152 (e.g., between the bulbous region 158 and the tube tip 154). Similarly, a seal 164 can be disposed between the coolant tip 156 and the wall 132 of the power module 102 (e.g., between the hole wall of the wall 132 and the protruding region 160 of the coolant tip 156). The seals 162, 164 can be formed of a common material or different materials. The seals 162, 164 can be, for example, elastomeric O-rings or RTV silicone seals.

[0065] Now referring Figure 8 , the cooling bar 170 can be a one-piece, integral, and integrally formed cooling bar 170. The cooling bar 170 can extend through the wall 132 of the power module 102 and into the coolant channel 134 of the power module 102. The cooling bar 170 can define a body portion 172 that extends within, extends out of, and extends through the potting material 126. The cooling bar 170 can further include a tip portion 174 that can be disposed in the coolant channel 134 of the power module 102 and can extend within the coolant channel 134 of the power module 102.

[0066] The tip portion 174 can define a plurality of spaced-apart elongated fins 176. In Figure 8 the method shown, the tip portion 174 can include two fins 176. In this way, the cooling bar 170 can be in the form of a finned bus bar.

[0067] The cooling bar 170 can be fixed to the wall 132 and can also include one or more seals as discussed with respect to the cooling bar 150. Thus, the cooling bar 170 can effect heat transfer between the potting material 126 and the coolant passing through the coolant channel 134 (as shown by arrow 142).

[0068] Referring Figure 9 , in yet another method, the cooling bar 180 can be a multi-component cooling bar. The cooling bar 180 can include a tube portion 182 that extends within the potting material 126 and defines a tube tip portion 184 that extends out of the potting material 126. The tube portion 182 can be a hollow tube portion that defines an internal cavity or can be a solid tube portion without an internal cavity. The cooling bar 180 can further include a coolant tip 186 that is fixed to the tube tip portion 184. The coolant tip 186 can extend through the wall 132 of the power module 102 and into the coolant channel 134 of the power module 102.

[0069] The tip portion 184 of the tube can define a plurality of spaced-apart elongated fins 186 extending from the plate region 188. More specifically, the tip portion 184 of the tube can define an array of at least four spaced-apart elongated fins 186. In this way, the cooling strip 170 can be in the form of a fin strip. In Figure 9 the method shown, the tip portion 184 of the tube can be a 5×5 array, including twenty fins 176. However, any suitable array (e.g., 2x2, 3x3, 4x4, or 6x6 or more) can be provided. Additionally, the array can be an asymmetric array having a first number of fins in a first direction and a second number of fins in a second direction, the second number being different from the first number.

[0070] In Figure 9 the method shown, the plate region 188 is a solid plate region without an internal cavity. In Figure 10 the method shown, the plate region 188 is a hollow plate region defining an internal cavity 190. The internal cavity 190 can be in fluid communication with the internal cavity of the tube portion 182 of the cooling strip 180.

[0071] Furthermore, as Figure 10 shown, the tube portion 182 of the cooling strip 180 can be provided with one or more internal threads.

[0072] Now referring to Figure 11 and Figure 12 , the inverter system controller (ISC) module 200 can include a power module 202 adapted to receive coolant (as shown by arrow 204) through a coolant passage 206, the coolant passage 206 being at least partially defined by a wall 208 of the power module 202.

[0073] The capacitor assembly 210 can be disposed adjacent to the power module 202. The capacitor assembly 210 can include one or more capacitor units 212 disposed within a potting material 214. The capacitor assembly 210 can also include one or more cooling strips 220. The one or more cooling strips 220 can include a first tip 222 and a second tip 224. The first tip 222 and the second tip 224 can extend through the wall 208 of the power module 202. The first tip 222 and the second tip 224 can also define a first opening 226 and a second opening 228.

[0074] In at least one method, the first tip 222 can be a coolant receiving tip adapted to receive coolant in an expected coolant flow path (as shown by arrow 204), and the second tip 224 can be a coolant discharge tip disposed downstream of the first tip 222 in the expected coolant flow path.

[0075] The capacitor assembly 210 may also include a hollow body 230 that extends between a first tip 222 and a second tip 224 and at least partially extends within the potting material 126. The first openings 226 and the second openings 228 of the first tip 222 and the second tip 224 may be adapted to permit fluid communication between the coolant channels 206 of the power module 202 and the hollow body 230.

[0076] In at least one method, the hollow body 230 may define an inlet tube portion 232 having a first central axis 234. The hollow body 230 may also define an intermediate tube portion 236 having a second central axis 238. The second central axis 238 may be angularly offset from the first central axis 234. For example, the second central axis 238 may be angularly offset from the first central axis 234 by an angle of approximately 90 degrees. The hollow body 230 may also define an outlet tube portion 240 having a third central axis 242. The third central axis 242 may be angularly offset from the second central axis 238. For example, the third central axis 242 may be angularly offset from the second central axis 238 by an angle of approximately 90 degrees. In this way, the third central axis 242 may be generally parallel to the first central axis 234.

[0077] In at least one method, the inlet tube portion 232 and the outlet tube portion 240 may be arranged in contact with the potting material 214, and the intermediate tube portion 236 may not be in contact with the potting material 214. For example, the intermediate tube portion 236 may be arranged outside the housing 250 of the capacitor assembly 210. More specifically, the intermediate tube portion 236 may be supported by a support region 252 extending from the housing 250 of the capacitor assembly 210.

[0078] In yet another method, the intermediate tube portion 236 may be in contact with the potting material 214. In this method, the intermediate tube portion 236 may extend within the housing 240 and be in contact with the potting material 214 between the inlet tube portion 232 and the outlet tube portion 240.

[0079] In at least one method, the cooling bar 240 is formed by a plurality of discrete components. In this way, the first tip 222 may be rigidly fixed to the inlet tube portion 232, and the second tip 224 may be rigidly fixed to the outlet tube portion 240. The multi-discrete-component cooling bar 240 may have tip portions fixed to the body portion, as described in various methods elsewhere herein. In at least another method, the first tip 222, the second tip 224, and the hollow body 230 are integrally formed.

[0080] Reference Figure 13, In yet another method, the cooling bar 260 can be a multi-component cooling bar. The cooling bar 260 can include a tube portion 262 that extends within the potting material 126 and defines a tube tip 264 that extends out of the potting material 126. The cooling bar 260 can further include a coolant tip 266 that is fixed to the tube tip 264. The coolant tip 266 can extend through the wall 132 of the power module 102 and into the coolant channel 134 of the power module 102.

[0081] The coolant tip 266 can be fixed to the tube tip 244 in any suitable manner. In at least one method, the coolant tip 266 can be fixed to the tube tip 264 by interference fit (e.g., press fit, snap fit) engagement. In another method, the tube tip 264 and the coolant tip 266 can be provided with complementary threaded regions to allow threaded engagement between the tube tip 264 and the coolant tip 266.

[0082] The coolant tip 266 can similarly be fixed to the wall 132 of the power module 102 by interference fit (e.g., press fit, snap fit) engagement. In yet another method, the wall 132 (e.g., at the hole in the wall 132) and the coolant tip 266 can be provided with complementary threaded regions to allow threaded engagement between the wall 132 and the coolant tip 266.

[0083] As Figure 13 shown, the coolant tip 266 can have an internal boss or protrusion 268 that can extend into the inner bore of the tube tip 264. The coolant tip 266 can further include an annular skirt that can, for example, extend around the entire outer surface of the tube tip 264. In this way, the surface contact between the coolant tip 266 and the tube tip 264 can be increased. Thus, the heat transfer between the potting material 126 and the coolant passing through the coolant channel 134 can be improved.

[0084] While the foregoing describes exemplary embodiments, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are descriptive words rather than limiting words, and it is to be understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously mentioned, the features of the various embodiments may be combined to form additional embodiments that may not be explicitly described or shown in the present invention. Although the various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, one of ordinary skill in the art will recognize that one or more features or characteristics may be compromised to achieve the desired overall system attributes, depending on the particular application and implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Thus, embodiments that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for a particular application.

[0085] According to the present invention, an inverter system is provided having: a power module that defines a coolant passage for receiving coolant; a capacitor assembly disposed adjacent to the power module, the capacitor assembly including a housing; potting material disposed within the housing; a plurality of power supplies disposed within the potting material; and a cooling bar that extends within the potting material between the power supplies and further extends out of the potting material and into the power module.

[0086] According to one embodiment, the cooling bar defines a hollow tube that extends through a wall of the power module and into the coolant passage of the power module.

[0087] According to one embodiment, the cooling bar is a multi-component cooling bar including a tube that extends within the potting material and defines a tube tip that extends out of the potting material; and a coolant tip secured to the tube tip, the coolant tip extending through a wall of the power module and into the coolant passage of the power module.

[0088] According to one embodiment, the cooling bar extends through a wall of the power module and into the coolant passage of the power module, wherein the cooling bar defines a tip portion disposed within the coolant passage, and wherein the tip portion defines a plurality of spaced-apart elongated fins.

[0089] According to one embodiment, the tip portion defines an array of at least four spaced-apart elongated fins.

[0090] According to one embodiment, at least a portion of the cooling bar that extends within the potting material defines a hollow tube having a first cavity.

[0091] According to one embodiment, the tip portion defines a hollow tip portion having a second cavity in fluid communication with the first cavity.

[0092] According to one embodiment, the tip portion is a substantially solid tip portion without an internal cavity.

[0093] According to one embodiment, the capacitor assembly includes (N - 2) / 2 cooling bars, where N is the number of power supplies disposed within the potting material.

[0094] According to the present invention, there is provided an inverter system control module having: a power module adapted to receive coolant; a capacitor assembly adjacent to the power module, including capacitor units disposed within a potting material; and a cooling bar having first and second tips that extend through a wall of the power module and define first and second openings; and a hollow body that extends between the first and second tips and at least partially extends within the potting material.

[0095] According to one embodiment, the first tip is a coolant receiving tip and the second tip is a coolant discharge tip disposed downstream of the intended coolant flow path, and the first and second openings of the first and second tips are adapted to permit fluid communication between the coolant channels of the power module and the hollow body.

[0096] According to one embodiment, the hollow body may define an inlet tube portion having a first central axis, an intermediate tube portion having a second central axis that is angularly offset from the first central axis, and an outlet tube portion having a third central axis that is angularly deviated from the second central axis and substantially parallel to the first central axis.

[0097] According to one embodiment, the inlet tube portion and the outlet tube portion are disposed in contact with the potting material, and the intermediate tube portion is not in contact with the potting material.

[0098] According to one embodiment, the cooling bar is a multi - discrete component cooling bar, and the first tip is rigidly fixed to the inlet tube portion and the second tip is rigidly fixed to the outlet tube portion.

[0099] According to the present invention, there is provided an electrified vehicle having: a DC power source configured to supply power to an electric drive system of the vehicle; an inverter system control (ISC) circuit coupled to the power source and configured to receive DC power from the power source; wherein the ISC circuit includes a power module defining coolant channels for receiving coolant; a capacitor assembly disposed adjacent to the power module, the capacitor assembly including a housing; a potting material disposed within the housing; a plurality of power supplies disposed within the potting material; and a cooling bar that extends between the power supplies within the potting material and further extends out of the potting material and into the power module.

[0100] According to one embodiment, the potting material comprises a thermally conductive electrical insulating material.

[0101] According to one embodiment, the power source is a capacitor unit.

[0102] According to one embodiment, the capacitor assembly comprises at least one of an input capacitor and a DC link capacitor.

[0103] According to one embodiment, the cooling bar is a multi-component cooling bar comprising a tube extending within the potting material and defining a tube tip extending out of the potting material; and a coolant tip fixed to the tube tip, the coolant tip extending through the wall of the power module and into the coolant channel of the power module.

[0104] According to one embodiment, the cooling bar extends through the wall of the power module and into the coolant channel of the power module, wherein the cooling bar defines a tip portion disposed within the coolant channel, and wherein the tip portion defines a plurality of spaced-apart elongated fins.

Claims

1. An inverter system, comprising: A power module that defines a coolant passage for receiving coolant; A capacitor assembly disposed adjacent to the power module, the capacitor assembly comprising: A housing; Potting material disposed within the housing; A plurality of power supplies disposed within the potting material; and Cooling bars that extend within the potting material between the power supplies and further extend out of the potting material and into the power module.

2. The inverter system according to claim 1, wherein the cooling bar defines a hollow tube that extends through a wall of the power module and into the coolant passage of the power module.

3. The inverter system according to claim 1, wherein the cooling bar is a multi-component cooling bar, comprising: A tube that extends within the potting material and defines a tube tip that extends out of the potting material; And A coolant tip that is fixed to the tube tip, the coolant tip extending through a wall of the power module and into the coolant passage of the power module.

4. The inverter system according to claim 1, wherein the cooling bar extends through a wall of the power module and into the coolant passage of the power module, wherein the cooling bar defines a tip portion disposed within the coolant passage, and wherein the tip portion defines a plurality of spaced-apart elongated fins.

5. The inverter system according to claim 4, wherein the tip portion defines an array of at least four spaced-apart elongated fins.

6. The inverter system according to claim 4, wherein at least a portion of the cooling bar that extends within the potting material defines a hollow tube having a first cavity.

7. The inverter system according to claim 6, wherein the tip portion defines a hollow tip portion having a second cavity that is in fluid communication with the first cavity.

8. The inverter system according to claim 6, wherein the tip portion is a substantially solid tip portion without an internal cavity.

9. The inverter system according to claim 1, wherein the capacitor assembly includes (N - 2) / 2 cooling bars, where N is the number of power supplies disposed within the potting material.

10. An inverter system control module, comprising: A power module adapted to receive coolant; A capacitor assembly adjacent to the power module, the capacitor assembly comprising: Capacitor units disposed within potting material; and Cooling bars having: A first tip and a second tip that extend through a wall of the power module and define a first opening and a second opening; and A hollow body that extends between the first tip and the second tip and extends at least partially within the potting material.

11. The inverter system control module according to claim 10, wherein the first tip is a coolant receiving tip and the second tip is a coolant discharge tip disposed downstream of an expected coolant flow path, and wherein the first opening and the second opening of the first tip and the second tip are adapted to permit fluid communication between the coolant passage of the power module and the hollow body.

12. The inverter system control module according to claim 11, wherein the hollow body defines an inlet tube portion having a first central axis, an intermediate tube portion having a second central axis that is angularly offset from the first central axis, and an outlet tube portion having a third central axis that is angularly deviated from the second central axis and is substantially parallel to the first central axis.

13. The inverter system control module according to claim 12, wherein the inlet tube portion and the outlet tube portion are arranged to contact the potting material, and wherein the intermediate tube portion does not contact the potting material.

14. The inverter system control module according to claim 12, wherein the cooling bar is a multi-discrete component cooling bar, and wherein the first tip is rigidly fixed to the inlet tube portion and the second tip is rigidly fixed to the outlet tube portion.

15. An electrified vehicle, comprising: A DC power source configured to provide power to the vehicle's electric drive system; An inverter system control circuit coupled to the power source and configured to receive DC power from the power source; Wherein the inverter system control circuit includes: A power module that defines a coolant passage for receiving coolant; A capacitor assembly disposed adjacent to the power module, the capacitor assembly including: A housing; A potting material disposed within the housing; A plurality of power supplies disposed within the potting material; and A cooling bar that extends between the power supplies within the potting material and further extends out of the potting material and into the power module.

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