Power module cold plate and motor controller

Abstract

This invention provides a cold plate for power modules and a motor controller, which can solve the problems of low heat dissipation efficiency and poor performance of liquid-cooled radiators in the prior art. The cold plate for power modules includes a base plate with grooves on both opposite sides. A partition plate is formed between the two grooves, separating them. The partition plate has connecting holes connecting the two grooves. Two cover plates cooperate with the two grooves to form a closed space. Multiple parallel fins are provided on the inner side of each cover plate. Each fin cooperates with the corresponding side of the partition plate to form a closed flow channel. A fixing block is also provided on the inner side of each cover plate, with fastener through holes for fixing the power module. The flow channels on both sides of the partition plate are connected in series through the connecting holes to form a main flow channel. The base plate or cover plate has an inlet for refrigerant to enter at the upstream of the main flow channel and an outlet for refrigerant to flow out at the downstream of the main flow channel.

Description

Technical Field

[0001] This invention relates to the field of liquid cooling plate technology, specifically to a cold plate for power modules and a motor controller. Background Technology

[0002] With the development of electric vehicle technology, the market demands increasingly higher levels of performance from electric vehicles. Improving motor power and driving range has become a future trend for electric vehicles. The motor drive system includes a motor controller that controls the motor. This controller can invert the DC power input from the battery into high-voltage electricity and adjust the motor speed in real time based on signals such as motor temperature and speed. The core component of the motor controller is the power module. When the motor is required to output more power, the motor controller must output a correspondingly larger current. This results in greater power loss for the power module, primarily in the form of heat loss. Therefore, heat dissipation of the power module is crucial for the motor controller.

[0003] In recent years, liquid-cooled plates have been increasingly used in high-power-density equipment due to their advantages of uniform heat distribution and indirect, pollution-free cooling. For example, a liquid-cooled radiator disclosed in patent document CN201204783Y, published on March 4, 2009, can exchange heat with power modules mounted on it, achieving cooling of the device or equipment. This liquid-cooled radiator includes an upper and lower heat sink plate that fit together during use. The sides of the two heat sink plates facing away from each other are used to mount common power modules such as IGBTs, while the sides facing each other have channels for refrigerant flow. A thermally conductive baffle is placed between the two heat sink plates, dividing the flow channels on the two heat sink plates into upper and lower flow channels. The thermally conductive baffle also has connecting holes that connect the two flow channels, thus connecting the upper and lower flow channels in series.

[0004] This liquid-cooled radiator can simultaneously dissipate heat from the power modules on both sides. Furthermore, the series-connected upper and lower flow channels allow for more thorough heat exchange between the refrigerant and the heat sink, controlling the temperature rise of the power modules and making their operation more stable. However, since the two heat sinks need to be connected to the power modules, fastener perforations must be provided on the heat sinks. To ensure connection strength, the heat sinks need to be quite thick, which increases the heat transfer path between the refrigerant and the power modules, reducing heat dissipation efficiency and resulting in poor heat dissipation performance. Summary of the Invention

[0005] The purpose of this invention is to provide a cold plate for power modules, which can solve the problems of low efficiency and poor performance of liquid cooling radiators in the prior art when dissipating heat from power modules. Another purpose of this invention is to provide a motor controller using this cold plate, which can stably control the temperature rise and has good working stability.

[0006] To achieve the above objectives, the cold plate for the power module in this invention adopts the following technical solution:

[0007] Cold plates for power modules include:

[0008] The substrate has grooves on both opposite sides, and a partition is formed between the two grooves to separate them. The partition has connecting holes that connect the two grooves.

[0009] Two cover plates are respectively fitted with two grooves to form a closed space. Multiple parallel fins are provided on the inner side of each cover plate. Each fin fits with the corresponding side of the partition plate to form a closed flow channel. A fixing block located at the side is also provided on the inner side of each cover plate. The fixing block is provided with fastener through holes for fixing the power module.

[0010] The flow channels on both sides of the partition are connected in series through connecting holes to form a main flow channel. The substrate or cover plate is provided with an inlet for refrigerant to enter at the upstream of the main flow channel, and an outlet for refrigerant to flow out at the downstream of the main flow channel.

[0011] Its beneficial effects are as follows: the fins on the two cover plates and the bottom of the corresponding grooves form flow channels. The fins increase the heat exchange area between the cover plates and the refrigerant in the flow channels, improving the cooling effect and allowing the heat of the power module to be transferred towards the interior of the substrate along the cover plates and fins; the fixing blocks provided on the cover plates provide processing space for fastener perforation, allowing technicians to reduce the thickness of the cover plates, shorten the heat transfer path between the power module and the refrigerant, and improve the heat dissipation efficiency; the power module can obtain good heat dissipation through the cold plate in this invention.

[0012] Furthermore, the fins are arranged in a serpentine pattern to form serpentine flow channels on both sides of the baffle.

[0013] Its beneficial effects are as follows: the use of serpentine fins to make the single-layer flow channel arranged in a serpentine pattern increases the flow path of the refrigerant, allowing the refrigerant to exchange heat more fully with the cover plate and power module, thereby improving the heat dissipation effect.

[0014] Furthermore, each groove is provided with two parallel and spaced vertical walls, one end of which is connected to the groove wall, and the other end extends to the bend common to all flow channels.

[0015] Its beneficial effects are: using vertical walls can not only support the cover plate and increase the heat exchange area, but also cooperate with the bends of the single-layer flow channel to prevent short circuits in the flow channel.

[0016] Furthermore, the substrate has outwardly extending thickened portions at its corners, and the liquid inlet and outlet are correspondingly located on the thickened portions.

[0017] Its beneficial effect is that by setting the liquid outlet and liquid inlet on the thickened part, the liquid outlet and liquid inlet are far away from the main body of the flow channel, thus avoiding excessive temperature difference that would affect heat transfer.

[0018] Furthermore, the outlet and inlet are arranged on the same side of the thickened part, and the outlet and inlet are partially closed. The outlet is only connected to the flow channel on one side of the partition, and the inlet is only connected to the flow channel on the other side of the partition.

[0019] Its advantages are that the outlet and inlet are arranged on the same side, which makes it easier for operators to process and assemble.

[0020] Furthermore, the thickness of the partition separating the two grooves is 4-8mm.

[0021] Its beneficial effects are as follows: the smaller thickness of the partition can shorten the heat exchange path of the refrigerant in the two grooves, making the heat exchange speed and effect of the refrigerant in the two grooves better, reducing the temperature difference of the upstream and downstream refrigerant in the main flow channel, and ensuring the heat dissipation effect of the power module.

[0022] To achieve the above objectives, the motor controller in this invention adopts the following technical solution:

[0023] The motor controller includes a cold plate and a power module disposed on the cold plate. The cold plate includes:

[0024] The substrate has grooves on both opposite sides, and a partition is formed between the two grooves to separate them. The partition has connecting holes that connect the two grooves.

[0025] Two cover plates are respectively fitted with two grooves to form a closed space. Multiple parallel fins are provided on the inner side of each cover plate. Each fin fits with the corresponding side of the partition plate to form a closed flow channel. A fixing block located at the side is also provided on the inner side of each cover plate. The fixing block is provided with fastener through holes for fixing the power module.

[0026] The flow channels on both sides of the partition are connected in series through connecting holes to form a main flow channel. The substrate or cover plate is provided with an inlet for refrigerant to enter at the upstream of the main flow channel, and an outlet for refrigerant to flow out at the downstream of the main flow channel.

[0027] Its beneficial effects are as follows: the fins on the two cover plates and the bottom of the corresponding grooves form flow channels. The fins increase the heat exchange area between the cover plates and the refrigerant in the flow channels, improving the cooling effect and allowing the heat of the power module to be transferred towards the interior of the substrate along the cover plates and fins; the fixing blocks set on the cover plates provide processing space for fastener perforation, allowing technicians to reduce the thickness of the cover plates, shorten the heat transfer path between the power module and the refrigerant, and improve the heat dissipation efficiency; the power module can obtain good heat dissipation through the cold plate in this invention, and the temperature rise of the power module itself can be well controlled, thereby ensuring the working stability of the motor controller.

[0028] Furthermore, the fins are arranged in a serpentine pattern to form serpentine flow channels on both sides of the baffle.

[0029] Its beneficial effects are as follows: the use of serpentine fins to make the single-layer flow channel arranged in a serpentine pattern increases the flow path of the refrigerant, allowing the refrigerant to exchange heat more fully with the cover plate and power module, thereby improving the heat dissipation effect.

[0030] Furthermore, each groove is provided with two parallel and spaced vertical walls, one end of which is connected to the groove wall, and the other end extends to the bend common to all flow channels.

[0031] Its beneficial effects are: using vertical walls can not only support the cover plate and increase the heat exchange area, but also cooperate with the bends of the single-layer flow channel to prevent short circuits in the flow channel.

[0032] Furthermore, the substrate has outwardly extending thickened portions at its corners, and the liquid inlet and outlet are correspondingly located on the thickened portions.

[0033] Its beneficial effect is that by setting the liquid outlet and liquid inlet on the thickened part, the liquid outlet and liquid inlet are far away from the main body of the flow channel, thus avoiding excessive temperature difference that would affect heat transfer.

[0034] Furthermore, the outlet and inlet are arranged on the same side of the thickened part, and the outlet and inlet are partially closed. The outlet is only connected to the flow channel on one side of the partition, and the inlet is only connected to the flow channel on the other side of the partition.

[0035] Its advantages are that the outlet and inlet are arranged on the same side, which makes it easier for operators to process and assemble.

[0036] Furthermore, the thickness of the partition separating the two grooves is 4-8mm.

[0037] Its beneficial effects are as follows: the smaller thickness of the partition can shorten the heat exchange path of the refrigerant in the two grooves, making the heat exchange speed and effect of the refrigerant in the two grooves better, reducing the temperature difference of the upstream and downstream refrigerant in the main flow channel, and ensuring the heat dissipation effect of the power module. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the structure of the cold plate and the power module cooperating part in the motor controller of the present invention;

[0039] Figure 2 This is a schematic diagram of the substrate structure of the cold plate in this invention;

[0040] Figure 3 for Figure 2 Top view;

[0041] Figure 4 This is a schematic diagram of the liquid inlet and liquid outlet on the substrate in this invention;

[0042] Figure 5 This is a schematic diagram of the structure of the lower cover plate in this invention;

[0043] Figure 6 for Figure 5 Top view;

[0044] Figure 7 This is a schematic diagram of the structure of the upper cover plate in this invention.

[0045] In the figure: 10-substrate; 11-top groove; 12-first vertical wall; 13-second vertical wall; 14-thickened part; 141-liquid inlet; 142-liquid outlet; 15-connecting hole; 16-partition; 20-upper cover plate; 21-fin; 22-first fixing block; 23-second fixing block; 30-lower cover plate; 31-fin; 32-first fixing block; 33-second fixing block; 40-power module; 50-screw; 60-pipe connector. Detailed Implementation

[0046] The specific implementation of the cold plate for the motor controller and power module in this invention will now be described with reference to the accompanying drawings.

[0047] like Figure 1 The diagram illustrates one embodiment of the motor controller of this invention: The motor controller includes multiple power modules 40, whose input terminals are simultaneously connected in parallel to an external DC power supply, and whose output terminals are connected to the motor to provide AC power to the motor. The motor controller also includes a cooling plate for dissipating heat from the power modules 40. The power modules 40 are mounted on both sides of the cooling plate, and heat exchange occurs between the cooling medium flowing within the cooling plate and the power modules 40, thereby reducing the temperature of the power modules 40 and controlling their temperature rise.

[0048] The relative positions of the various parts of the motor controller are now described using the up-down and left-right directions shown in the accompanying drawings: (e.g.) Figure 1 and 2As shown, the cold plate in the motor controller includes a base plate 10, with grooves on its top and bottom surfaces. These grooves provide space to accommodate refrigerant. The cold plate also includes an upper cover plate 20 and a lower cover plate 30 that cooperate with the base plate 10. These two cover plates, in conjunction with the grooves on the top and bottom surfaces of the base plate 10, form a closed space for the refrigerant to flow. Figure 3 As shown, the two grooves are divided into a top groove 11 and a bottom groove according to their positions. A partition 16 separates the two grooves, and a connecting hole 15 is provided on the partition 16 to connect the two grooves. The two grooves are connected only through the connecting hole 15. In this embodiment, the substrate 10 and the cover plate are made of aluminum alloy, which has high strength and good thermal conductivity, ensuring the effect and efficiency of heat transfer.

[0049] like Figure 5 , Figure 6 and Figure 7 As shown, the upper cover plate 20 is provided with fins 21, and the lower cover plate 30 is provided with fins 31. Taking the lower cover plate 30 as an example, multiple fins 31 are arranged in parallel, and each fin 31 is arranged in a serpentine pattern. The intervals between adjacent fins 31 form a space for refrigerant flow. When the upper cover plate 20 and the lower cover plate 30 are respectively covered on the substrate 10, two adjacent fins 31 can contact the corresponding side of the partition plate 16 and cooperate with the side of the partition plate 16 to form a closed flow channel. The fins in the top groove 11 and the bottom groove form a single-layer flow channel with upper and lower layers. The single-layer flow channel is arranged in a serpentine pattern, which can increase the length of the refrigerant flow path and improve the heat dissipation effect on the power module 40. In this embodiment, the two cover plates are connected to the substrate 10 by friction welding, which has good sealing performance.

[0050] like Figure 5 As shown, fixing blocks are provided on the inner sides of the upper cover plate 20 and the lower cover plate 30. The fixing blocks have fastener through holes, the openings of which penetrate the outer sides of both cover plates, allowing threaded fasteners such as screws 50 to pass through. The fixing blocks provide machining space for the fastener through holes on the cover plates. When power modules 40 are arranged on the cold plate, each power module 40 has through holes corresponding to the positions of the fixing blocks. Technicians can use the fastener through holes on the fixing blocks to screw in the screws 50 to fix each power module 40. Taking the lower cover plate 30 as an example, the fixing blocks in this embodiment are divided into two types according to their shape: a first fixing block 32 with an oblong cross-section and a second fixing block 33 with a circular cross-section. The first fixing block 32 has two fastener through holes, while the second fixing block 33 has only one fastener through hole. The second fixing block 33 is positioned at the corner of the lower cover plate 30, while the first fixing block 32 is positioned along the long side of the lower cover plate 30. Figure 7As shown, the upper cover plate 20 is also provided with a first fixing block 22 and a second fixing block 23, and their structure and arrangement are the same as the two types of fixing blocks on the lower cover plate 30.

[0051] like Figure 6 and Figure 7 As shown, the fins on the upper cover plate 20 and the lower cover plate 30 have two bent portions. Vertical walls that mate with these two bent portions are provided in the top groove 11 and the bottom groove. These vertical walls support the two cover plates and prevent short circuits in the flow channels. Taking the top groove 11 as an example, the arrangement of the vertical walls is described. The two vertical walls in the top groove 11 are the first vertical wall 12 and the second vertical wall 13. In the left-right direction, the first vertical wall 12 connects to the left side of the top groove 11 and extends to the right, while the second vertical wall 13 connects to the right side of the top groove 11 and extends to the left. In this case, the two vertical walls are arranged facing each other. In the front-back direction, the two vertical walls are staggered, with the first vertical wall 12 located in front of the second vertical wall 13. Both vertical walls face the common bend of the upper flow channel. The way the vertical walls in the bottom groove mate with the corresponding fins is the same as the way the vertical walls in the top groove 11 mate with the fins, and will not be repeated.

[0052] like Figure 3 and Figure 4 As shown, a thickened portion 14 extending outward is provided at the corner of the substrate 10. An inlet 141 and an outlet 142 are provided in the thickened portion 14. The single-layer flow channels in the top groove 11 and the bottom groove are connected in series through connecting holes 15 on the partition plate 16. The two single-layer flow channels combine to form the main flow channel of the cold plate. The main flow channel has a layered structure, with its upstream and downstream sections correspondingly located at the thickened portion 14 of the substrate 10. The inlet 141 and outlet 142 on the thickened portion 14 have the same diameter and are arranged parallel to each other in the left-right direction. The inlet 141 is located on the left side, with the upper part of the inlet 141 being closed, allowing the inlet 141 to connect only to the single-layer flow channel in the bottom groove. The outlet 142 is located on the right side, with the lower part of the outlet 142 being closed, allowing the outlet 142 to connect only to the single-layer flow channel in the top groove 11. The partial closure of the inlet 141 and outlet 142 ensures that the two single-layer flow channels do not short-circuit. A pipe connector 60 is correspondingly provided at the inlet 141 and outlet 142, and the pipe connector 60 is fixed to the substrate 10 by applying liquid PTFE tape.

[0053] The motor controller is equipped with six power modules 40, which are used in conjunction with a dual three-phase motor. When assembling the power modules 40 and the cold plate, the operator divides the six power modules 40 into two groups of three, which are fixed to the two cover plates by screws 50 and fixing blocks. At this time, the refrigerant introduced into the cold plate can dissipate heat from the two groups of power modules 40. At the same time, the group arrangement also reduces the size of the cold plate and the motor controller.

[0054] When the operator uses the motor controller of this invention, the input terminals of each power module 40 are connected to a DC power supply, and the output terminals are connected to the corresponding phases of the dual three-phase motor, realizing the function of converting DC power into AC power. The pipe joints 60 of the cold plate are respectively connected to containers containing refrigerant, so that the containers and cold plates combine to form a cooling circulation system. The refrigerant enters the single-layer flow channel in the bottom groove through the liquid inlet 141, and enters the single-layer flow channel in the top groove 11 along the serpentine flow channel, and finally flows out from the liquid outlet 142 of the cold plate.

[0055] The partition 16 separating the top groove 11 and the bottom groove is 6mm thick. The refrigerant in the top groove 11 and the bottom groove can be transferred through the partition 16. The thinner partition 16 can reduce the heat transfer path, allowing the refrigerant in the two grooves to exchange heat faster and better, and reducing the temperature steps in the upstream and downstream of the main flow channel.

[0056] In other embodiments, the fins on the cover plate can be arranged in a straight line, in which case the flow channel formed by the cover plate and the substrate is also straight.

[0057] In other embodiments, the groove on the substrate may no longer have vertical walls, and the flow channel for refrigerant flow may be formed by the cooperation of the fins on the cover plate with the bottom of the groove.

[0058] In other embodiments, the outlet and inlet can be respectively disposed on the two cover plates, instead of being limited to the scheme of providing a thickened portion on the substrate and placing the inlet and outlet on the thickened portion; or, the outlet and inlet can be directly disposed on the side wall of the substrate, without providing a thickened portion to provide processing space for the outlet and inlet.

[0059] In other embodiments, the sizes of the outlet and inlet can be adjusted accordingly. The sizes of the outlet and inlet are smaller than the thickness of the single-layer flow channel, so the solution of partially closing the outlet and inlet is no longer necessary.

[0060] In other embodiments, the partition can have a thickness in the range of 4-8mm, such as 4mm, 5mm, 7mm, or 8mm, and is not limited to 6mm.

[0061] The structure and usage method of the cold plate for the power module in this invention, as well as the technical effects it can achieve, are the same as the structure, usage method, and technical effects of the cold plate in the above-mentioned motor controller embodiment. Therefore, the implementation method of the cold plate for the power module will not be described again.

[0062] The specific embodiments described above further illustrate the inventive purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A cold plate for power modules, characterized in that: include: The substrate has grooves on both opposite sides, and a partition is formed between the two grooves to separate them. The partition has connecting holes that connect the two grooves. Two cover plates, each engaging with two grooves to form a closed space, are provided with multiple parallel fins on the inner side of each cover plate. Each fin engages with the corresponding side of the partition plate to form a closed flow channel. The fins are arranged in a serpentine pattern so that the flow channels on both sides of the partition plate form a serpentine flow channel. Each cover plate also has a fixing block located at the side, and the fixing block has fastener through holes for fixing the power module. Each groove is provided with parallel and spaced vertical walls that correspond to the bends of the serpentine flow channel. One end of the vertical wall is connected to the groove wall, and the other end extends to the bends common to all the flow channels. The flow channels on both sides of the partition are connected in series through connecting holes to form a main flow channel. The substrate or cover plate is provided with an inlet for refrigerant to enter at the upstream of the main flow channel, and an outlet for refrigerant to flow out at the downstream of the main flow channel. The connecting holes are located away from the inlet and outlet in the extension direction of the flow channels on both sides of the partition. The substrate has a thickened portion extending outward at the corner. The liquid inlet and liquid outlet are respectively located on the same side of the thickened portion. The liquid outlet and liquid inlet are partially closed. The liquid outlet is only connected to the flow channel on one side of the partition, and the liquid inlet is only connected to the flow channel on the other side of the partition.

2. The cold plate for power modules according to claim 1, characterized in that: The number of vertical walls is two.

3. The cold plate for power modules according to claim 1, characterized in that: The thickness of the partition separating the two grooves is 4-8mm.

4. A motor controller, comprising a cold plate and a power module disposed on the cold plate, characterized in that: The cold plate is the power module cold plate as described in any one of claims 1-3.

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