Power module assembly for vehicle power inverters

Abstract

This disclosure provides a "power module assembly for a vehicle power inverter". A power module assembly includes a plate defining cavities and arranged in a stacked configuration such that the cavities engage to define coolant chambers interleaved with the plate. The assembly also includes clips having power modules encapsulated within a frame. The frame has outwardly projecting spacers, and each clip is disposed in a corresponding chamber within the cavities, wherein the spacers contact a wall of the corresponding chamber to form a coolant passage between the wall and the clip.

Description

Technical Field

[0001] This disclosure relates to a power module assembly for a power inverter used in motor vehicles. Background Technology

[0002] Vehicles, such as battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and full hybrid electric vehicles (FHEVs), include a traction battery pack to serve as an energy source for one or more electric motors. The traction battery includes components and systems that help manage vehicle performance and operation. A power inverter is electrically connected between the battery and the motor to convert direct current (DC) from the battery into alternating current (AC) compatible with the motor. The power inverter can also function as a rectifier to convert AC from the motor into DC compatible with the battery. Summary of the Invention

[0003] According to one embodiment, a power module assembly includes a plate defining cavities and arranged in a stacked configuration such that the cavities engage to define coolant chambers interleaved with the plate. The assembly also includes cards having power modules encapsulated within a frame. The frame has outwardly projecting spacers, and each card is disposed in a corresponding chamber within the cavities, wherein the spacers contact a wall of the corresponding chamber to form a coolant channel between the wall and the card.

[0004] According to another embodiment, a power module assembly includes a stacked board comprising adjacent first and second plates defining a first cavity and a second cavity, respectively. The cavities cooperate to form a coolant chamber. A first clip is located in the coolant chamber such that a first coolant channel is defined between the first plate and the first clip, and a second coolant channel is defined between the second plate and the first clip.

[0005] According to another embodiment, a power module assembly includes plates, each plate including first and second opposing main sides, a first cavity recessed into the first main side, a second cavity recessed into the second main side, and a partition wall having a first surface of a base plate forming the first cavity and a second surface of a base plate forming the second cavity. The plates are arranged in a linear stack such that adjacent cavities in the first and second cavities cooperate to define coolant chambers intersecting with the partition walls. The assembly also includes cards having opposing first and second main sides, and a power module encapsulated in a frame having spacers extending from the second main sides. Each card is disposed in one of the coolant chambers, wherein the spacer is attached to a corresponding partition wall to support the card within the coolant chamber, such that a first coolant channel is formed between the second main side of the card and the corresponding partition wall, and a second coolant channel is formed between the first main side of the card and another corresponding partition wall. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of an example hybrid vehicle.

[0007] Figure 2 This is a schematic diagram of a variable voltage converter and a power inverter.

[0008] Figure 3 This is a perspective view of the power module assembly of the power inverter.

[0009] Figure 4 This is a perspective view of the power module assembly card.

[0010] Figure 5 This is a side view of the card.

[0011] Figure 6A This is a perspective view of the top side of the central board of the power module assembly.

[0012] Figure 6B This is a perspective view of the bottom side of the central panel.

[0013] Figure 7 This is an exploded perspective view of the power module assembly.

[0014] Figure 8 This is a cross-sectional view of the power module assembly.

[0015] Figure 9 It is a perspective view of the connection features used to fix adjacent plates to each other.

[0016] Figure 10 This is a cross-sectional view of the power module assembly. Detailed Implementation

[0017] Detailed embodiments of the invention are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely illustrative of the invention, which can be embodied in various forms and alternatives. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ the invention in different ways.

[0018] Examples of PHEVs in Figure 1 The vehicle 16 is depicted and is generally referred to as vehicle 16. Vehicle 16 includes a transmission 12 and is propelled by at least one electric motor 18 with selective assistance from an internal combustion engine 20. The electric motor 18 may be... Figure 1 The image depicts an alternating current (AC) electric motor 18, designated as "motor" 18. Motor 18 receives electrical power and provides torque for vehicle propulsion. Motor 18 also functions as a generator to convert mechanical power into electrical power via regenerative braking.

[0019] The transmission 12 can be a power-split configuration. The transmission 12 includes a first motor 18 and a second motor 24. The second motor 24 can be... Figure 1 The AC electric motor is depicted as a "generator" 24. Similar to the first motor 18, the second motor 24 receives electricity and provides output torque. The second motor 24 also functions as a generator to convert mechanical power into electrical power and optimize the power flow through the transmission 12. In other embodiments, the transmission does not have a power-split configuration.

[0020] The transmission 12 may include a planetary gear unit 26, which includes a center gear 28, a planetary gear carrier 30, and a ring gear 32. The center gear 28 is connected to the output shaft of the second motor 24 to receive torque from the generator. The planetary gear carrier 30 is connected to the output shaft of the engine 20 to receive torque from the engine. The planetary gear unit 26 combines the generator torque and the engine torque, providing a combined output torque around the ring gear 32. The planetary gear unit 26 functions as a continuously variable transmission (CVT) without any fixed or "stage" ratios.

[0021] The transmission 12 may also include a one-way clutch (OWC) and a generator brake 33. The OWC is coupled to the output shaft of the engine 20 to allow the output shaft to rotate in only one direction. The OWC prevents the transmission 12 from driving the engine 20 in the opposite direction. The generator brake 33 is coupled to the output shaft of the second motor 24. The generator brake 33 can be activated to "brake" or prevent rotation of the output shafts of the second motor 24 and the center gear 28. Alternatively, the OWC and generator brake 33 can be eliminated and replaced with control strategies for the engine 20 and the second motor 24.

[0022] The transmission 12 may further include a countershaft with intermediate gears, said intermediate gears including a first gear 34, a second gear 36, and a third gear 38. A planetary output gear 40 is connected to a ring gear 32. The planetary output gear 40 meshes with the first gear 34 to transmit torque between the planetary gear unit 26 and the countershaft. An output gear 42 is connected to the output shaft of a first motor 18. The output gear 42 meshes with the second gear 36 to transmit torque between the first motor 18 and the countershaft. The transmission output gear 44 is connected to a drive shaft 46. The drive shaft 46 is coupled to a pair of driven wheels 48 via a differential 50. The transmission output gear 44 meshes with the third gear 38 to transmit torque between the transmission 12 and the driven wheels 48.

[0023] Vehicle 16 includes an energy storage device for storing electrical energy, such as a traction battery 52. ​​Battery 52 is a high-voltage battery capable of outputting power to operate a first motor 18 and a second motor 24. When the first motor 18 and the second motor 24 operate as generators, battery 52 also receives power from the first motor 18 and the second motor 24. Battery 52 is a battery pack consisting of several battery modules (not shown), each battery module containing multiple battery cells (not shown). Other embodiments of vehicle 16 contemplate different types of energy storage devices, such as capacitors and fuel cells (not shown) to supplement or replace battery 52. ​​A high-voltage bus electrically connects battery 52 to the first motor 18 and the second motor 24.

[0024] The vehicle includes a Battery Energy Control Module (BECM) 54 for controlling the battery 52. ​​The BECM 54 receives inputs indicating vehicle and battery conditions, such as battery temperature, voltage, and current. The BECM 54 calculates and estimates battery parameters, such as the battery's state of charge (SOC) and battery capacity. The BECM 54 provides outputs (BSOC, P...). cap It indicates the battery's state of charge (BSOC) and the battery's electrical capacity to other vehicle systems and controllers (P). cap ).

[0025] Vehicle 16 includes a DC-DC converter or variable voltage converter (VVC) 10 and an inverter 56. VVC 10 and inverter 56 are electrically connected between traction battery 52 and first motor 18, and between battery 52 and second motor 24. VVC 10 “raises” or increases the voltage potential of the power supplied by battery 52. ​​According to one or more embodiments, VVC 10 also “lowers” ​​or decreases the voltage potential of the power supplied to battery 52. ​​Inverter 56 inverts the DC power supplied by battery 52 (via VVC 10) into AC power to operate motors 18, 24. Inverter 56 also rectifies the AC power supplied by motors 18, 24 back to DC to charge traction battery 52. ​​Other embodiments of transmission 12 include multiple inverters (not shown), such as one inverter associated with each motor 18, 24. VVC 10 includes an inductor assembly 14.

[0026] The transmission 12 includes a transmission control module (TCM) 58 for controlling motors 18 and 24, VVC 10, and inverter 56. The TCM 58 is configured to monitor the position, speed, and power consumption of motors 18 and 24, etc. The TCM 58 also monitors electrical parameters (e.g., voltage and current) at various locations within the VVC 10 and inverter 56. The TCM 58 provides output signals corresponding to this information to other vehicle systems.

[0027] Vehicle 16 includes a Vehicle System Controller (VSC) 60, which communicates with other vehicle systems and controllers to coordinate their functions. Although shown as a single controller, VSC 60 may also include multiple controllers, which can be used to control multiple vehicle systems according to overall vehicle control logic or software.

[0028] Vehicle controllers, including VSC 60 and TCM 58, typically include any number of microprocessors, ASICs, ICs, memories (e.g., FLASH, ROM, RAM, EPROM, and / or EEPROM), and software code that work together to perform a range of operations. The controller also includes predetermined data or "lookup tables" based on calculated and test data stored in memory. VSC 60 communicates with other vehicle systems and controllers (e.g., BECM 54 and TCM 58) via one or more wired or wireless vehicle connections using common bus protocols (e.g., CAN and LIN). VSC 60 receives inputs (PRND) indicating the current position of transmission 12 (e.g., park, reverse, neutral, or drive). VSC 60 also receives inputs (APP) indicating the accelerator pedal position. VSC 60 provides outputs indicating desired wheel torque, desired engine speed, and alternator braking commands to TCM 58; and contactor control to BECM 54.

[0029] Vehicle 16 includes an engine control module (ECM) 64 for controlling engine 20. VSC 60 provides an output (desired engine torque) to ECM 64, the output being based on multiple input signals including an APP and corresponding to the driver's request for vehicle propulsion.

[0030] If vehicle 16 is a PHEV, battery 52 can periodically receive AC energy from an external power source or the power grid via charging port 66. Vehicle 16 also includes an on-board charger 68, which receives AC energy from charging port 66. Charger 68 is an AC / DC converter that converts the received AC energy into DC energy suitable for charging battery 52. ​​Furthermore, charger 68 supplies DC energy to battery 52 during recharging. Although shown and described in the context of PHEV 16, it should be understood that inverter 56 can be implemented in other types of electric vehicles, such as HEVs or BEVs.

[0031] refer to Figure 2 It shows an electrical schematic of the VVC 10 of the power inverter 56 and the power module assembly 57. The VVC 10 may include one or more power modules having at least a first switching unit 70 and a second switching unit 72 for boosting the input voltage (V... bat To provide output voltage (V) dc The first switching unit 70 may include a first transistor 74 connected in parallel to the first diode 76, but with its polarity switched (anti-parallel). In one embodiment, switch 70 may be a reverse-biased insulated-gate bipolar transistor (RCIGBT). The second switching unit 72 may include a second transistor 78 connected in anti-parallel to the second diode 80. Each transistor 74, 78 may be any type of controllable switch (e.g., an insulated-gate bipolar transistor (IGBT) or a field-effect transistor (FET)). Additionally, each transistor 74, 78 may be individually controlled by TCM 58. The inductor assembly 14 is depicted as an input inductor connected in series between the traction battery 52 and the switching units 70, 72. When current is supplied, inductor 14 generates magnetic flux. As the current flowing through inductor 14 changes, a time-varying magnetic field is generated, and a voltage is induced. Other embodiments of VVC 10 include alternative circuit configurations.

[0032] The power module assembly 57 may include multiple power modules stacked within the assembly. Each power module may include one or more half-bridges 82 having a positive DC lead 84 connected from the battery to a positive DC node and a negative DC lead 86 connected from the battery to a negative DC node. Each half-bridge 82 may also include a first switching unit 88 and a second switching unit 90. The first switching unit 88 may include a first transistor 92 connected in parallel to a first diode 94. The second switching unit 90 may include a second transistor 96 connected in parallel to a second diode 98. The first transistor 88 and the second transistor 96 may be IGBTs or FETs. The first switching unit 88 and the second switching unit 90 may be similar to switching units 70, 72. The first and second switching units of each of the half-bridges 82 convert the DC power from the battery into a single-phase AC output at an AC lead 100. Each of the AC leads 100 is electrically connected to a motor 18 or a generator 24.

[0033] Figures 3 to 10 The accompanying discussion describes an example power module assembly for inverter 56. (Reference) Figure 3 The example power module assembly 110 includes multiple plates linearly arranged in a stack 112. The stack 112 includes multiple central plates 114 sandwiched between a pair of end plates 116. Multiple clips 118 are interleaved with the plates 114, 116. The plates and clips 118 are characterized by mating to define multiple coolant chambers within the stack 112. Coolant circulates through these chambers to cool or heat the clips 118. (This will be described in more detail below.)

[0034] Plates 114 and 116 may include connection features 122 for securing adjacent plates to each other. Connection feature 122 may include a first portion on one of the adjacent plates and a second portion on the other. The first and second portions engage with each other to connect the plates. Each of plates 114 and 116 has a protrusion 120 on an opposite side of the plate. Each of the protrusions 120 may define a hole for receiving a connecting rod 124 passing through it. The connecting rod 124 may be used to secure plates 114 and 116 to each other and to secure the power module assembly 110 to a vehicle. The threaded end of the connecting rod 124 may be attached to a vehicle bracket 126 to secure the power module assembly 110 to the vehicle.

[0035] A coolant manifold 128 supplies coolant to and from the power module assembly 110. The manifold 128 can be mounted to an end plate 116a. The end plate 116a can define an inlet port and an outlet port that are in fluid communication with a coolant chamber. An inlet 130 of the manifold 128 is connected to the inlet port defined in the end plate 116a, and an outlet 132 of the manifold 128 is connected to the outlet port defined in the end plate 116a. A distal end of the coolant manifold 128 is connected to a thermal management system configured to supply coolant to the manifold 128 to heat or cool the power module assembly 110 depending on operating conditions.

[0036] refer to Figure 4 and Figure 5 Each of the cards 118 includes a power module 134 encapsulated in a frame 138. The power module 134 includes one or more switching units 136 sandwiched between a pair of substrates. Each of the substrates includes an outer plate 140 that is electrically isolated from the electrical component portions of the power module 134.

[0037] Each card 118 includes opposing main surfaces 142, 143. A frame 138 may be open on the main surfaces 142, 143 to expose an outer panel 140. This allows coolant to flow directly through the outer panel 140 and more effectively heat / cool the power module 134. The frame 138 has a first protruding wall 144 extending across the main surface 143 and located on a first edge 156 of the card 118, and a second protruding wall 146 extending across the main surface 143 and located on a second edge 158 of the card 118. The first protruding wall 144 and the second protruding wall 146 are spaced apart to define a channel 148. The first protruding wall 144 and the second protruding wall 146 may be integrally formed with the frame 138. The first wall 144 and the second wall 146 may be referred to as spacers.

[0038] refer to Figure 6A and Figure 6B Each of the central plates 114 may include a top side 164 and a bottom side 166, which may be referred to as a main side. The top side 164 may include one or more mating surfaces 168 and a recessed top cavity 170, and the bottom side 166 may include one or more mating surfaces 171 and a recessed bottom cavity 172. Each central plate 114 may include a partition wall 174 separating the top cavity 170 and the bottom cavity 172. The partition wall 174 includes a top surface 176 of a bottom plate defining the top cavity 170 and a bottom surface 178 of a bottom plate defining the bottom cavity 172. The partition wall 174 may define an inlet port 180 and an outlet port 182 disposed on opposite sides of the plate 114. The top cavity 170 may be recessed deeper than the bottom cavity. The depth of the top cavity may be substantially equal to the thickness of the card 118. In an alternative embodiment, each of the plates has only a top cavity, and the bottom side of the plate is flat.

[0039] refer to Figure 7 and Figure 8 Each of the end plates 116 further defines a cavity 186. For example, end plate 116a defines cavity 186a, and end plate 116b defines cavity 186b. The central plates 114 are arranged in a stack such that the top sides 164 and bottom sides 166 of adjacent plates are abutted against each other with mating surfaces 168 and 171 in contact, and the top cavities 170 and bottom cavities 172 of adjacent plates engage to define coolant chambers 190 intersecting with partition walls 174. Gaskets 192 may be disposed between adjacent plates to seal coolant chambers 190. The top side 164 may define a recessed gasket channel for receiving gaskets 192. The end plates 116 sandwich the stack of central plates 114 in the middle such that the cavity 186b of end plate 116b engages with the cavity of the topmost central plate 114 to form an additional coolant chamber 191.

[0040] Each of the cards 118 is disposed within one of the coolant chambers 190, 191. In the illustrated embodiment, each chamber 190, 191 receives a single card 118, but in other embodiments, multiple cards may be disposed within each of the coolant chambers. The cards 118 are disposed in the coolant chamber 190 such that the main surfaces 142 and 143 are spaced apart from the partition wall 174. This allows coolant to flow across both main surfaces for efficient cooling of the power module 134. The cards 118 are supported in the chamber by spacers (e.g., a first protruding wall 144 and a second protruding wall 146). The spacers may be configured to support the cards in the middle of the chamber, i.e., the distance between the main surface 142 and the associated partition wall 174 is substantially equal to the distance between the main surface 143 and the associated partition wall 174. For example, each card 118 may be secured by attaching the first protruding wall 144 and the second protruding wall 146 to the top surface 176 of the partition wall 174. Alternatively, the protruding wall may be attached to the bottom surface 178 of the partition wall.

[0041] Each of the coolant chambers 190 and 191 includes a first coolant channel 194 above the card and a second coolant channel 196 below the card to provide bi-lateral cooling. The first channel 194 is defined between the main side 142 and the upper wall of chamber 190, and the second channel 196 is defined between the main side 143 and the lower wall of chamber 190. The first channel 194 of the top chamber 191 is defined between the main side 142 and the upper wall of chamber 191. In most cases, the upper wall is the bottom surface 178 of one of the partition walls 174, and the lower wall is the top surface 176 of the other partition wall 174.

[0042] refer to Figure 7 and Figure 9As described above, the stack 112 can be secured together by connection features 122 on plates 114 and 116. Connection features 122 can be snap-fits, clips, etc. For example, each connection feature 122 may include a first portion formed on one plate and a second portion formed on an adjacent plate. The first portion may be a protrusion 200 extending from the underside 166 of the plate to engage with a slot 206 on the adjacent plate. The protrusion 200 may include a distal end 202 having a barb 204. The slot 206 may include an inclined surface 208 that guides the barb 204 into a recess 210 of the slot 206. The wall 212 of the recess 210 is configured to engage with the barb 204 to prevent the first and second portions from separating from each other.

[0043] refer to Figure 8 and Figure 10 The stack 112 may have a parallel cooling arrangement in which coolant flows from the supply side 214 through chambers 190, 191 and to the return side 216. During operation, coolant is supplied to the power module assembly 110 via manifold 128. Manifold 128 supplies coolant to inlet 222 of the stack 112. Inlet 222 is aligned with inlet port 180 of partition wall 174, thereby allowing coolant to circulate axially through the stack 112. Coolant then flows from the supply side 214 into chambers 190, 191, where coolant is separated between a first coolant channel 194 and a second coolant channel 196. As the coolant circulates above the card, it absorbs (or provides) heat from the power module 134. Outlet port 182 of partition wall 174 is also axially aligned, thereby allowing coolant to circulate back toward end plate 116a. Return conduit 198 connects the return side 216 and outlet 132.

[0044] While exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms included in the claims. The language used in this specification is descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. Although various embodiments may be described as providing advantages or superiority over other embodiments or prior art implementations in terms of one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system properties, depending on the specific application and implementation.

[0045] According to the present invention, a power module assembly is provided, comprising: plates, each plate defining a cavity and arranged in a stacked manner such that the cavities engage to define coolant chambers interleaved with the plates; and clips, each clip including a power module encapsulated in a frame having outwardly projecting spacers, wherein each clip is disposed in a corresponding chamber within the cavities, wherein the spacers contact a wall of the corresponding chamber to form a coolant channel between the wall and the clip.

[0046] According to one embodiment, the chambers are in fluid communication with each other.

[0047] According to one embodiment, each plate includes a partition wall having a first surface defining a wall of one of the coolant chambers and a second surface defining a wall of another coolant chamber in the coolant chambers.

[0048] According to one embodiment, each of the partition walls defines an inlet opening and an outlet opening.

[0049] According to one embodiment, each of the spacers is attached to a corresponding partition wall among the partition walls.

[0050] According to one embodiment, each of the cards defines an opposing main face, and the spacer is part of the frame that extends over the main face and is attached to the wall of the respective chamber.

[0051] According to one embodiment, the spacer includes a pair of walls extending from the main surface of the card.

[0052] According to one embodiment, the coolant channel is located between the pair of walls.

[0053] According to one embodiment, the plates are fixed together by a connecting feature including a protrusion extending from a first plate and a slot portion defined in a second plate and configured to receive the protrusion.

[0054] According to the present invention, a power module assembly is provided, comprising: plates, each plate including first and second opposing main sides, a first cavity recessed into the first main side, a second cavity recessed into the second main side, and a partition wall having a first surface of a base plate forming the first cavity and a second surface of a base plate forming the second cavity, wherein the plates are arranged in a linear stack such that adjacent cavities in the first and second cavities cooperate to define coolant chambers intersecting with the partition wall; and cards, each card having opposing first and second main sides and including a power module encapsulated in a frame having a spacer extending from the second main side, wherein each card is disposed in one of the coolant chambers, wherein the spacer is attached to a corresponding partition wall of the partition wall to support the card within the coolant chamber such that a first coolant channel is formed between the second main side of the card and the corresponding partition wall, and a second coolant channel is formed between the first main side of the card and another corresponding partition wall of the partition wall.

[0055] According to one embodiment, the spacer is a pair of walls.

[0056] According to one embodiment, the power module includes at least one switching unit.

[0057] According to the present invention, a power module assembly is provided, comprising: a stacked plate including adjacent first and second plates defining a first cavity and a second cavity respectively, the first cavity and the second cavity cooperating to form a coolant chamber; and a first clip located in the coolant chamber such that a first coolant channel is defined between the first plate and the first clip, and a second coolant channel is defined between the second plate and the first clip.

[0058] According to one embodiment, the first card has a spacer connecting the main surface of the first card and the first plate.

[0059] According to one embodiment, the spacer extends outward from the main surface and is attached to the wall of the first card.

[0060] According to one embodiment, the first card includes a frame and a power module encapsulated by the frame, the frame having a pair of spaced-apart walls extending over the main surface of the first card to attach to the first plate.

[0061] According to one embodiment, the first coolant passage is defined between the spaced-out walls.

[0062] According to one embodiment, the first plate and the second plate are fixed together by a connecting feature including a protrusion extending from the first plate and a slot portion defined in the second plate and configured to receive the protrusion.

[0063] According to one embodiment, the protruding portion is integrally formed with the first plate, and the slot portion is integrally formed with the second plate.

[0064] According to one embodiment, the stacked plate includes adjacent third and fourth plates defining a third cavity and a fourth cavity, respectively, the third cavity and the fourth cavity cooperating to form a second coolant chamber; and further includes a second clip located in the coolant chamber such that a third coolant channel is defined between the third plate and the second clip, and a fourth coolant channel is defined between the fourth plate and the second clip.

Claims

1. A power module assembly, comprising: Plates, each defining a cavity and arranged in a stacked manner, such that the cavities cooperate to define coolant chambers intersecting with the plates; as well as The card includes a power module encapsulated in a frame having outwardly projecting spacers, wherein each card is disposed in a corresponding chamber within the cavity, wherein the spacers contact the wall of the corresponding chamber to form a coolant channel between the wall and the card.

2. The power module assembly of claim 1, wherein the chambers are in fluid communication with each other.

3. The power module assembly of claim 1, wherein each plate includes a partition wall having a first surface defining a wall of one of the coolant chambers and a second surface defining a wall of another coolant chamber in the coolant chambers.

4. The power module assembly of claim 3, wherein each of the partition walls defines an inlet opening and an outlet opening.

5. The power module assembly of claim 3, wherein each of the spacers is attached to a corresponding spacer wall of the spacers.

6. The power module assembly of claim 1, wherein each of the cards defines an opposing main face, and the spacer is part of the frame extending over the main face and attached to the wall of the respective chamber.

7. The power module assembly of claim 1, wherein the spacer includes a pair of walls extending from the main surface of the card.

8. The power module assembly of claim 7, wherein the coolant channel is located between the pair of walls.

9. The power module assembly of claim 1, wherein the boards are secured together by a connection feature including a protrusion extending from a first board and a slot portion defined in a second board and configured to receive the protrusion.

10. The power module assembly of claim 1, wherein the power module includes at least one switching unit.

11. A power module assembly, comprising: The plates each include opposing first and second main sides, a first cavity recessed into the first main side, a second cavity recessed into the second main side, and a partition wall having a first surface of a base plate forming the first cavity and a second surface of a base plate forming the second cavity, wherein the plates are arranged in a linear stack such that adjacent cavities in the first and second cavities cooperate to define coolant chambers intersecting with the partition wall. as well as The cards, each having an opposing first and second main surface and including a power module encapsulated in a frame having a spacer extending from the second main surface, wherein each of the cards is disposed in one of the coolant chambers, wherein the spacer is attached to a corresponding partition wall to support the card within the coolant chamber, such that a first coolant channel is formed between the second main surface of the card and the corresponding partition wall, and a second coolant channel is formed between the first main surface of the card and another corresponding partition wall.

12. The power module assembly of claim 11, wherein the spacer is a pair of walls.

13. The power module assembly of claim 11, wherein the power module includes at least one switching unit.

14. A power module assembly, comprising: A stacked plate, the stacked plate including adjacent first plates and second plates defining a first cavity and a second cavity respectively, the first cavity and the second cavity cooperating to form a coolant chamber; as well as A first card, located in the coolant chamber, has a spacer connecting the main surface of the first card and the first plate, such that a first coolant channel is defined between the first plate and the first card, and a second coolant channel is defined between the second plate and the first card.

15. The power module assembly of claim 14, wherein the spacer extends outward from the main surface and is attached to the wall of the first card.

16. The power module assembly of claim 14, wherein the power module includes at least one switching unit.

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