Direct cooling of inverter switches

Abstract

The switch of the inverter module is placed in a coolant channel, which is configured to be immersed in the coolant in the coolant channel and includes: a first terminal, which is placed on a first plane and is configured to be connected to a direct current (DC) reference potential; a second terminal, which is placed on a second plane and is configured to be connected to an alternating current (AC) reference potential; a gate, an emitter, and a collector; a first cooling feature, which extends away from the first and second planes, directly contacts the first terminal, and is configured to allow coolant to flow therethrough; and a second cooling feature, which extends away from the first cooling feature, the first plane, and the second plane, directly contacts the second terminal, and is configured to allow coolant to flow therethrough.

Description

Technical Field

[0001] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. The work of the presently named inventors within the scope described in this section and aspects of this specification that may not have been prior art at the time of filing are neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0002] The present disclosure relates to vehicle propulsion systems, and more particularly to cooling of switches of an inverter module. Background Art

[0003] Some types of vehicles include only an internal combustion engine that produces propulsion torque. Electric vehicles may not include an internal combustion engine, and may rely on one or more electric motors for propulsion.

[0004] A hybrid vehicle includes both an internal combustion engine and one or more electric motors. Some types of hybrid vehicles utilize an electric motor and an internal combustion engine in an attempt to achieve greater fuel efficiency than would be possible using only the internal combustion engine. Some types of hybrid vehicles utilize an electric motor and an internal combustion engine to achieve greater torque output than the internal combustion engine alone can achieve.

[0005] Some exemplary types of hybrid vehicles include parallel hybrid vehicles, series hybrid vehicles, and other types of hybrid vehicles. In a parallel hybrid vehicle, an electric motor operates in parallel with the engine to combine the power and range advantages of the engine with the efficiency and regenerative braking advantages of the electric motor. In a series hybrid vehicle, the engine drives a generator to generate electricity for the electric motor, and the electric motor drives the transmission. This allows the electric motor to take on some of the power duties of the engine, which can permit the use of a smaller and potentially more efficient engine. Summary of the invention

[0006] In a feature, a switch cooling system includes: a coolant channel; a switch of an inverter module, the switch being disposed in the coolant channel and being configured to be immersed in the coolant in the coolant channel, and including: a first terminal, the first terminal being disposed on a first plane and being configured to be connected to a direct current (DC) reference potential; a second terminal, the second terminal being disposed on a second plane and being configured to be connected to an alternating current (AC) reference potential; a gate, an emitter, and a collector; a first cooling feature, the first cooling feature extending away from the first and second planes, directly contacting the first terminal, and being configured to allow coolant to flow therethrough; and a second cooling feature, the second cooling feature extending away from the first cooling feature, the first plane, and the second plane, directly contacting the second terminal, and being configured to allow coolant to flow therethrough.

[0007] In other features, the first and second planes are parallel.

[0008] In other features, the first cooling feature extends perpendicularly away from the first and second planes.

[0009] In other features, the second cooling feature extends perpendicularly away from the first and second planes.

[0010] In other features, the second switch of the inverter module is disposed in the coolant channel, is configured to be immersed in the coolant in the coolant channel, and includes: a third terminal, which is disposed on a third plane and is configured to be connected to a second DC reference potential; a second gate, a second emitter, and a second collector, the second gate, the second emitter, and the second collector are disposed between the second and third planes; and a third cooling feature, which extends away from the second and third planes, directly contacts the third terminal, and is configured to allow coolant to flow therethrough.

[0011] In other features, an electrical insulator is disposed between (a) the gate, the emitter, and the collector and (b) the second gate, the second emitter, and the second collector.

[0012] In other features, first, second, and third electrical conductors are electrically connected to the first, second, and third terminals and extend through the coolant passage to an exterior of the coolant passage.

[0013] In other features, the first cooling feature includes a member extending perpendicular to the first and second planes.

[0014] In other features, the first feature includes: a plurality of parallel plates; and struts separating the plates from each other.

[0015] In other features, the struts extend perpendicular to the parallel plates.

[0016] In other features, the support is cylindrical.

[0017] In other features, the struts all have the same diameter.

[0018] In other features, the struts all have the same pitch.

[0019] In other features, the struts include a first strut having a first diameter and a second strut having a second diameter.

[0020] In other features, the first struts have a first pitch and the second struts have a second pitch, wherein the first pitch is different than the second pitch.

[0021] In other features, the first cooling feature includes: a first layer, the first layer including an inlet, an outlet, a first portion fluidly connected to the inlet, and a second portion fluidly connected to the outlet; a second layer, the second layer including a third portion fluidly connected to the first and second portions of the first layer; and a third layer, the third layer including a fourth portion fluidly connected to the first and second portions.

[0022] In other features, the first cooling feature includes: two parallel plates; and a helical member having a first rotational direction and disposed between the two parallel plates.

[0023] In other features, the first cooling feature further comprises: a second helical member having a second rotational direction and disposed between the two parallel plates.

[0024] In other features, the second rotational direction is different from the first rotational direction.

[0025] In other features, the first cooling feature includes a first material having uniform openings configured to allow coolant to flow therethrough and a second material having non-uniform openings configured to allow coolant to flow therethrough.

[0026] Other areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0027] The present disclosure also includes the following technical solutions.

[0028] Technical Solution 1. A switch cooling system, comprising:

[0029] Coolant channels;

[0030] A switch of an inverter module, the switch being disposed in the coolant channel, configured to be immersed in the coolant in the coolant channel, and comprising:

[0031] a first terminal disposed on a first plane and configured to be connected to a direct current (DC) reference potential;

[0032] a second terminal disposed on the second plane and configured to be connected to an alternating current (AC) reference potential;

[0033] a gate, an emitter and a collector, wherein the gate, the emitter and the collector are disposed between the first and second planes;

[0034] a first cooling feature extending away from the first and second planes, directly contacting the first terminal, and configured to allow coolant to flow therethrough; and

[0035] A second cooling feature extends away from the first cooling feature, the first plane, and the second plane, directly contacts the second terminal, and is configured to allow coolant to flow therethrough.

[0036] Technical Solution 2. The switch cooling system according to Technical Solution 1, wherein the first and second planes are parallel.

[0037] Technical Solution 3. The switch cooling system according to Technical Solution 1, wherein the first cooling feature extends vertically away from the first and second planes.

[0038] Technical Solution 4. The switch cooling system according to Technical Solution 1, wherein the second cooling feature extends vertically away from the first and second planes.

[0039] Technical Solution 5. The switch cooling system according to Technical Solution 1 further comprises a second switch of the inverter module, the second switch being disposed in the coolant channel and configured to be immersed in the coolant in the coolant channel, and comprising:

[0040] a third terminal disposed on a third plane and configured to be connected to a second DC reference potential;

[0041] a second gate, a second emitter, and a second collector, the second gate, the second emitter, and the second collector being disposed between the second and third planes; and

[0042] A third cooling feature extends away from the second and third planes, directly contacts the third terminal, and is configured to allow coolant to flow therethrough.

[0043] Technical Solution 6. The switch cooling system according to Technical Solution 5 further comprises an electrical insulator disposed between (a) the gate, the emitter and the collector and (b) the second gate, the second emitter and the second collector.

[0044] Technical Solution 7. The switch cooling system according to Technical Solution 5 further comprises first, second and third electrical conductors, which are electrically connected to the first, second and third terminals and extend through the coolant channel to the outside of the coolant channel.

[0045] Technical Solution 8. The switch cooling system according to Technical Solution 1, wherein the first cooling feature includes a component extending perpendicular to the first and second planes.

[0046] Technical Solution 9. The switch cooling system according to Technical Solution 1, wherein the first feature includes:

[0047] a plurality of parallel plates; and

[0048] Supports that separate the plates from each other.

[0049] Technical Solution 10. A switch cooling system according to Technical Solution 9, wherein the support pillar extends perpendicular to the parallel plates.

[0050] Technical Solution 11. A switch cooling system according to Technical Solution 9, wherein the support is cylindrical.

[0051] Technical Solution 12. A switch cooling system according to Technical Solution 11, wherein all of the pillars have the same diameter.

[0052] Technical Solution 13. A switch cooling system according to Technical Solution 11, wherein all of the pillars have the same pitch.

[0053] Technical Solution 14. The switch cooling system according to Technical Solution 11, wherein the pillar comprises a first pillar having a first diameter and a second pillar having a second diameter.

[0054] Technical Solution 15. The switch cooling system according to Technical Solution 14, wherein the first support has a first pitch and the second support has a second pitch, wherein the first pitch is different from the second pitch.

[0055] Technical Solution 16. The switch cooling system according to Technical Solution 1, wherein the first cooling feature comprises:

[0056] a first layer comprising an inlet, an outlet, a first portion fluidly connected to the inlet, and a second portion fluidly connected to the outlet;

[0057] a second layer comprising a third portion fluidly connected to the first and second portions of the first layer; and

[0058] A third layer includes a fourth portion fluidly connected to the first and second portions.

[0059] Technical Solution 17. The switch cooling system according to Technical Solution 1, wherein the first cooling feature comprises:

[0060] two parallel plates; and

[0061] A helical member has a first rotational direction and is disposed between the two parallel plates.

[0062] Technical Solution 18. The switch cooling system according to Technical Solution 17, wherein the first cooling feature further comprises:

[0063] A second helical member has a second rotational direction and is disposed between the two parallel plates.

[0064] Technical Solution 19. A switch cooling system according to Technical Solution 18, wherein the second rotation direction is different from the first rotation direction.

[0065] Technical Solution 20. The switch cooling system according to Technical Solution 1, wherein the first cooling feature comprises:

[0066] a first material having uniform openings configured to allow coolant to flow therethrough; and

[0067] A second material having non-uniform openings configured to allow coolant to flow therethrough. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] The present disclosure will become more fully understood based on the detailed description and accompanying drawings, in which:

[0069] Figure 1 is a functional block diagram of an exemplary vehicle system;

[0070] Figure 2 is a functional block diagram of an exemplary propulsion control system;

[0071] Figure 3 is a schematic diagram of an exemplary embodiment including an inverter module and a battery;

[0072] Figure 4 is a perspective view of an exemplary embodiment of a switch of a branch of an inverter module;

[0073] Figure 5 yes Figure 4 An exploded perspective view of an exemplary switch of a branch;

[0074] Figure 6 is a cross-sectional side view of an exemplary embodiment of a coolant passage and a branching switch;

[0075] Figure 7 yes Figure 6 A three-dimensional perspective view of an exemplary coolant channel and branch switch;

[0076] Figure 8 and Fig. 9 is a perspective view of an exemplary cooling feature and a bottom view of an exemplary plate of the cooling feature;

[0077] Figure 10-Figure 14 is a perspective view of an exemplary cooling feature; and

[0078] Fig.15 and Fig.16 A functional block diagram of an exemplary cooling system is included.

[0079] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. The dimensions of features of the drawings may not necessarily be drawn to scale. DETAILED DESCRIPTION

[0080] The internal combustion engine of a vehicle burns air and fuel in cylinders to produce propulsion torque. The engine can output torque to the wheels of the vehicle via a transmission. Some types of vehicles may not include an internal combustion engine, or the internal combustion engine may not be mechanically coupled to the vehicle's drivetrain.

[0081] The electric motor can be mechanically coupled to the shaft of the transmission. In some cases, the control module of the vehicle can apply power from the battery to the electric motor, causing the electric motor to output torque for vehicle propulsion. In other cases, the control module can disable the power flow to the electric motor and allow the transmission to drive the rotation of the electric motor. The electric motor generates power when driven by the transmission. When the voltage generated by the electric motor is greater than the voltage of the battery, the power generated by the electric motor can be used to recharge the battery. The control module switches one or more switches of the inverter module to apply power from the battery to the electric motor.

[0082] The switch (e.g., terminal) becomes relatively hot during switching. According to the present disclosure, the switch is immersed in a cooling fluid (e.g., dielectric fluid) to cool the switch. The switch includes a cooling feature that contacts the terminal to increase heat transfer away from the terminal and the switch.

[0083] Reference now Figure 1 , presents a functional block diagram of an exemplary vehicle system. Although a vehicle system for a hybrid vehicle is shown and will be described, the present disclosure is also applicable to electric vehicles, fuel cell vehicles, autonomous vehicles, and other types of vehicles that do not include an internal combustion engine. Moreover, although an example of a vehicle is provided, the present application is also applicable to non-vehicle embodiments that include one or more switches.

[0084] The engine 102 may combust an air / fuel mixture to produce drive torque. An engine control module (ECM) 114 controls the engine 102. For example, the ECM 114 may control actuation of engine actuators, such as a throttle valve, one or more spark plugs, one or more fuel injectors, a valve actuator, a camshaft phaser, an exhaust gas recirculation (EGR) valve, one or more boost devices, and other suitable engine actuators. In some types of vehicles (e.g., electric vehicles), the engine 102 may be omitted.

[0085] The engine 102 can output torque to a transmission 195. A transmission control module (TCM) 194 controls operation of the transmission 195. For example, the TCM 194 can control gear selection within the transmission 195 and one or more torque-transmitting devices (e.g., a torque converter, one or more clutches, etc.).

[0086] The vehicle system includes one or more electric motors, such as electric motor 198. At a given time, the electric motor can act as a generator or a motor. When acting as a generator, the electric motor converts mechanical energy into electrical energy. The electrical energy can be used, for example, to charge battery 199. When acting as a motor, the electric motor produces torque that can be used, for example, for vehicle propulsion. Although an example of an electric motor is provided, the vehicle can include more than one electric motor.

[0087] The motor control module 196 controls the power flow from the battery 199 to the electric motor 198 and from the electric motor 198 to the battery 199. The motor control module 196 applies the electric power from the battery 199 to the electric motor 198 to cause the electric motor 198 to output positive torque, such as for vehicle propulsion. The battery 199 may include, for example, one or more batteries and / or battery packs.

[0088] The electric motor 198 can output torque, for example, to an input shaft of the transmission 195 or an output shaft of the transmission 195. The clutch 200 can be engaged to couple the electric motor 198 to the transmission 195 and disengaged to decouple the electric motor 198 from the transmission 195. One or more gear devices can be implemented between the output of the clutch 200 and the input of the transmission 195 to provide a predetermined ratio between the rotation of the electric motor 198 and the rotation of the input of the transmission 195.

[0089] The motor control module 196 can also selectively convert the mechanical energy of the vehicle into electrical energy. More specifically, when the electric motor 198 is driven by the transmission 195 and the motor control module 196 does not apply power to the electric motor 198 from the battery 199, the electric motor 198 generates and outputs power via back electromotive force. The motor control module 196 can charge the battery 199 via the power output by the electric motor 198.

[0090] Reference now Figure 2 , presents a functional block diagram of an exemplary propulsion control system. The driver torque module 204 determines the driver torque request 208 based on the driver input 212. The driver input 212 may include, for example, an accelerator pedal position (APP), a brake pedal position (BPP), a cruise control input, and / or an autonomous input. In various embodiments, the cruise control input may be provided by an adaptive cruise control system that attempts to maintain at least a predetermined distance between the vehicle and an object in the path of the vehicle. The autonomous input may be provided by an autonomous driving system that controls the vehicle to move from one location to another while avoiding objects and other vehicles. The driver torque module 204 determines the driver torque request 208 based on one or more lookup tables that relate the driver input to the driver torque request. The APP and BPP may be measured using one or more APP sensors and BPP sensors, respectively.

[0091] The driver torque request 208 may be an axle torque request. Axle torque (including axle torque requests) refers to torque at the wheels. As discussed further below, propulsion torque (including propulsion torque requests) differs from axle torque in that propulsion torque may refer to torque at a transmission input shaft.

[0092] The axle torque arbitration module 216 arbitrates between the driver torque request 208 and other axle torque requests 220. Axle torque (torque at the wheels) may be generated by various sources including the engine 102 and / or one or more electric motors (e.g., the electric motor 198). Examples of other axle torque requests 220 include, but are not limited to, torque reductions requested by a traction control system when positive wheel slip is detected, torque increase requests to offset negative wheel slip, brake management requests to reduce axle torque to ensure that the axle torque does not exceed the ability of the brakes to hold the vehicle when the vehicle is stopped, and vehicle overspeed torque requests to reduce axle torque to prevent the vehicle from exceeding a predetermined speed. The axle torque arbitration module 216 outputs one or more axle torque requests 224 based on the results of arbitrating between the received axle torque requests 208 and 220.

[0093] In a hybrid vehicle, a hybrid module 228 can determine how much of the one or more axle torque requests 224 the engine 102 should generate and how much of the one or more axle torque requests 224 the electric motor 198 should generate. For simplicity, the example of the electric motor 198 will continue, but multiple electric motors may be used. The hybrid module 228 outputs one or more engine torque requests 232 to a propulsion torque arbitration module 236. The engine torque request 232 indicates a requested torque output of the engine 102.

[0094] The hybrid module 228 also outputs a motor torque request 234 to the motor control module 196. The motor torque request 234 indicates the requested torque output (positive or negative) of the electric motor 198. In a vehicle where the engine 102 is omitted (e.g., an electric vehicle) or where the engine 102 is not connected to output propulsion torque for the vehicle, the axle torque arbitration module 216 may output an axle torque request and the motor torque request 234 may be equal to the axle torque request. In the example of an electric vehicle, the ECM 114 may be omitted and the driver torque module 204 and the axle torque arbitration module 216 may be implemented within the motor control module 196.

[0095] In an electric vehicle, the driver torque module 204 may input the driver torque request 208 to the motor control module 196 , and components associated with controlling engine actuators may be omitted.

[0096] The propulsion torque arbitration module 236 converts the engine torque request 232 from the axle torque domain (torque at the wheels) to the propulsion torque domain (e.g., torque at the input shaft of the transmission). The propulsion torque arbitration module 236 arbitrates the converted torque request with other propulsion torque requests 240. Examples of other propulsion torque requests 240 include, but are not limited to, torque reduction for engine overspeed protection requests and torque increase for anti-stall requests. The propulsion torque arbitration module 236 may output one or more propulsion torque requests 244 as a result of the arbitration.

[0097] The actuator control module 248 controls actuators 252 of the engine 102 based on the propulsion torque request 244. For example, based on the propulsion torque request 244, the actuator control module 248 may control opening of a throttle valve, timing of spark provided by a spark plug, timing and amount of fuel injected by a fuel injector, cylinder activation / deactivation, intake and exhaust valve phasing, output of one or more boost devices (e.g., a turbocharger, a supercharger, etc.), opening of an EGR valve, and / or one or more other engine actuators. In various implementations, the propulsion torque request 244 may be adjusted or modified before being used by the actuator control module 248, for example to create a torque reserve.

[0098] The motor control module 196 controls the switching of switches of the inverter module 256 based on the motor torque request 234. The switching of the inverter module 256 controls the flow of power from the battery 199 to the electric motor 198. As such, the switching of the inverter module 256 controls the torque of the electric motor 198. The inverter module 256 also converts the power generated by the electric motor 198 and outputs the power to the battery 199, for example, to charge the battery 199.

[0099] The inverter module 256 includes a plurality of switches. The motor control module 196 switches the switches to convert the DC power from the battery 199 into alternating current (AC) power, and applies the AC power to the electric motor 198 to drive the electric motor 198. For example, the inverter module 256 can convert the DC power from the battery 199 into n-phase AC power, and apply the n-phase AC power to the n stator windings (e.g., a, b, and c, or u, v, and w) of the electric motor 198. In various embodiments, n is equal to 3. The rotor of the electric motor 198 is driven by the magnetic flux generated by the current passing through the stator windings. The rotor is connected to the output shaft of the electric motor 198 and drives it to rotate.

[0100] In various embodiments, one or more filters may be electrically connected between the inverter module 256 and the battery 199. The one or more filters may be implemented, for example, to filter the power flow to and from the battery 199. As an example, a filter including one or more capacitors and resistors may be electrically connected in parallel with the inverter module 256 and the battery 199.

[0101] Figure 3 A schematic diagram is included that includes an exemplary embodiment of an inverter module 256 and a battery 199. The high (positive, DC+) and low (negative, DC-) sides 304 and 308 are connected to the positive and negative terminals of the battery 199, respectively. The inverter module 256 is also connected between the high side 304 and the low side 308.

[0102] The inverter module 256 includes three branches, one branch connected to each phase of the electric motor 198. The first branch 312 includes first and second switches 316 and 320. The switches 316 and 320 each include a first terminal, a second terminal, and a control terminal. Each of the switches 316 and 320 can be an insulated gate bipolar transistor (IGBT), a field effect transistor (FET) (e.g., a metal oxide semiconductor FET (MOSFET)), or another suitable type of switch. In the examples of IGBTs and FETs, the control terminal is referred to as a gate.

[0103] A first terminal of the first switch 316 is connected to the high side 304. A second terminal of the first switch 316 is connected to a first terminal of a second switch 320. A second terminal of the second switch 320 may be connected to the low side 308. A node connected to the second terminal of the first switch 316 and the first terminal of the second switch 320 is connected to a first phase (e.g., a) of the electric motor 198.

[0104] The first branch 312 also includes first and second diodes 324 and 328 connected in anti-parallel to the switches 316 and 320, respectively. In other words, the anode of the first diode 324 is connected to the second terminal of the first switch 316, and the cathode of the first diode 324 is connected to the first terminal of the first switch 316. The anode of the second diode 328 is connected to the second terminal of the second switch 320, and the cathode of the second diode 328 is connected to the first terminal of the second switch 320. When the switches 316 and 320 are turned off (and open), when the output voltage of the electric motor 198 is greater than the voltage of the battery 199, the power generated by the electric motor 198 is transferred through the diodes 324 and 328. This charges the battery 199. The diodes 324 and 328 form one phase of the three-phase rectifier.

[0105] The inverter module 256 also includes second and third branches 332 and 336. The second and third branches 332 and 336 can be similar or identical (in circuitry) to the first branch 312. In other words, the second and third branches 332 and 336 can each include corresponding switches and diodes connected in the same manner as the first branch 312, such as switches 316 and 320 and diodes 324 and 328. For example, the second branch 332 includes switches 340 and 344 and anti-parallel diodes 348 and 352. The node connected to the second terminal of switch 340 and the first terminal of switch 344 is connected to the second stator winding (e.g., b) of the electric motor 198. The third branch 336 includes switches 356 and 360 and anti-parallel diodes 364 and 368. The node connected to the second terminal of switch 356 and the first terminal of switch 360 is connected to the third stator winding (e.g., c) of the electric motor 198.

[0106] Figure 4 is an exemplary perspective view of switches of the first branch 312 of the inverter module 256 . Figure 5 is an exploded perspective view of the switch of the first branch 312. The switches of the second and third branches 332 and 336 may be the same as the switch of the first branch 312.

[0107] The AC terminal 504 is connected to the phase of the electric motor 198. The positive DC terminal 508 is connected to the high side 304. The negative DC terminal 512 is connected to the low side 308. The AC terminal 504, the positive DC terminal 508, and the negative DC terminal 512 each include a cooling feature 516 extending vertically away from the switch, and a coolant flows through the cooling feature 516 to cool the switch of the first branch 312. Although the positive DC terminal 508 and the negative DC terminal 512 are shown as being relatively close to each other, the positive DC terminal 508 and the negative DC terminal 512 are separated and electrically isolated from each other. In various embodiments, an (electrical) insulator can be placed between the positive DC terminal 508 and the negative DC terminal 512. The AC terminal 504, the positive DC terminal 508, and the negative DC terminal 512 are made of a conductive material, such as aluminum, copper, or another suitable type of conductive material.

[0108] exist Figure 5 324 and 328 are shown in the example of FIG. Insulator 520 is disposed between first switch 316 and second switch 320 and electrically isolates first switch 316 from second switch 320. First switch 316 includes gate 524, emitter 528, and collector 532. Second switch 320 includes gate 536, emitter 540, and collector 544. As shown, emitters 528 and 540 may include multiple emitter portions. First and second switches 316 and 320 may be silicon switches, silicon carbide (SiC) switches, gallium nitride (GaN) switches, or another suitable type of switch.

[0109] Figure 6 A cross-sectional side view of a switch including coolant passage 604 and first branch 312 . Figure 7 A three-dimensional perspective view of a switch including a coolant channel 604 and a first branch 312. As shown, an enclosure 608 of the switch including the first branch 312 is disposed within the coolant channel 604. One or more spacers 612 may be implemented on the exterior of the enclosure and contact the interior wall of the coolant channel 604. Coolant flows through the coolant channel 604 and the cooling features 516 of the AC terminal 504, the positive DC terminal 508, and the negative DC terminal 512.

[0110] like Figure 5 As shown in , the switches can be arranged on several planes. For example, the first switch 316 and the first diode 324 can be arranged on a first plane, and the second switch 320 and the second diode 328 can be arranged on a second plane. The first and second planes can be parallel. The cooling features 516 of the AC terminal 504, the positive DC terminal 508, and the negative DC terminal 512 can each extend perpendicular to (normal to) the first and second planes. Figure 6 and Figure 7 As shown in FIG. 5 , leads 704 connected to AC terminal 504 , positive DC terminal 508 , and negative DC terminal 512 may extend through coolant passage 604 to be electrically connected to other components external to coolant passage 604 .

[0111] Figure 8 8 is a perspective view of an exemplary feature 804 of the negative DC terminal 512 and a bottom view of an exemplary plate 808. The cooling features of the AC terminal 504 and the positive DC terminal 508 may be the same as the cooling features 804.

[0112] The first plate 806 is electrically conductive and may contact one or more portions of one or more of the switches. The plate 806 is disposed on a plane that is horizontal to the plane of the switches.

[0113] Cooling feature 804 includes a plurality of plates, such as plates 808 - 1 , 808 - 2 , . . . , 808 -N (collectively referred to as plates 808 ) The plates 808 are disposed on different horizontal planes parallel to the plane of the switch and parallel to the plane of plate 806 .

[0114] The pillars 812 are formed on the bottom surface 816 of each of the plates 808 and extend away therefrom. The plates 808 and the pillars 812 may be made of a conductive material. The pillars 812 of the plates 808 may extend perpendicular to the plates 808. The pillars 812 may be cylindrical, for example, Figure 8Although an example of a cylindrical support is provided, support 812 may have another suitable shape. Support 812 may have the same diameter, spacing, and pitch, such as in Figure 8 In various embodiments, struts having two or more different diameters may be used, and two or more different strut spacings and / or pitches may be used. For example, Fig. 9 A perspective view of an exemplary feature 804 including negative DC terminal 512 and a bottom view of an exemplary plate 808. Fig. 9 In the example of , each of the plates 808 includes a first pillar 904 having a first diameter and a second pillar 908 having a second diameter. There is a first distance between the centers of the first pillars 904, and there is a second distance between the centers of the second pillars 908 that is different from the first distance.

[0115] exist Figure 8 and Fig. 9 In the example of FIG. 5 , a coolant may flow between the plates and between the supports to cool the switch.

[0116] In various embodiments, plates 804 and 808 may be replaced by features configured to move through multiple different planes parallel to the switch.

[0117] For example, Fig.10 is a perspective view of an exemplary cooling feature 1004 of the negative DC terminal 512. The cooling features of the AC terminal 504 and the positive DC terminal 508 may be the same as the features 804.

[0118] Feature 1004 includes at least three layers arranged in different planes parallel to the plane of the switch. Fig.10 The examples of FIG. 5 involve a three-layer example, but two or more layers may be used.

[0119] Fig.10 Also included are views of exemplary top and bottom layers 1008 and exemplary middle layers 1012. Middle layer 1012 is disposed between top and bottom layers 1008, for example, disposed on plane 1016. Top and bottom layers 1008 are disposed above and below middle layer 1012. For example, top layer 1008 can be disposed on plane 1020. Top and bottom layers 108 can be identical. Cross section 1024 is taken along plane 1028.

[0120] The middle layer 1012 may include an inlet 1032 and an outlet 1036, a first portion 1040, and a second portion 1044. The coolant flows through the inlet 1032 to the first portion 1040. The top and bottom layers 1008 include a third portion 1048 that receives the coolant from the first portion 1040 and flows the coolant to the second portion 1044. The second portion 1044 is fluidly connected to the outlet 1036, and the coolant flows out through the outlet 1036. An exemplary coolant flow path is provided on the cross section 1024.

[0121] Fig.11 A perspective view of an exemplary cooling feature 1104 including negative DC terminal 512. The cooling features of AC terminal 504 and positive DC terminal 508 may be the same as feature 1104.

[0122] Feature 1104 includes a plate 1108 disposed in a plane parallel to the plane of the switch. A support 1112 extends away from the plate 1108 (e.g., perpendicular to the plane of the plate 1108). Other plates 1116 extend away from the support 1112 (e.g., perpendicular to the support 1112) such that the plate 1116 and the support 1112 form a T-shape. The plate 1116 can be disposed along a plane parallel to the plane of the plate 1108. A coolant flows through a cavity between adjacent ones of the plates 1116.

[0123] One or more rotation inducing members 1120 are disposed in the cavities between adjacent ones of the plates 1116. The rotation inducing members 1120 may be spiral shaped. Fig.11 As shown in the example of , two rotation inducing members 1120 can be disposed in each cavity. As an example, the two rotation inducing members 1120 can include one right-handed spiral and one left-handed spiral to provide counter-rotating coolant flow, as shown by 1124. Alternatively, the two rotation inducing members 1120 can include two right-handed spirals or two left-handed spirals to provide co-rotating coolant flow, as shown by 1128 and 1132.

[0124] Fig.12 A perspective view of exemplary cooling features 1204 including negative DC terminal 512. The cooling features of AC terminal 504 and positive DC terminal 508 may be the same as feature 1204.

[0125] Feature 1204 may include a plate 1206 disposed in a plane parallel to the plane of the switch. Alternating rectangular blocks of structured material 1208 and unstructured material 1212 may be arranged in rows and columns on plate 1206. Fig.12 An exemplary illustration of structured material 1208 is provided on the right side of FIG. Structured material 1208 has the same openings throughout. Fig.12The bottom of the switch 1208 provides an exemplary illustration of the unstructured material 1212. Examples of the unstructured material 1212 include metal foam. A coolant flows through the structured material 1208 and the unstructured material 1212 to cool the switch.

[0126] Fig.13 is a perspective view of exemplary features 1304 of negative DC terminal 512 . Fig.13 Also included is a top view of exemplary feature 1304 . The cooling features of AC terminal 504 and positive DC terminal 508 may be the same as cooling feature 1304 .

[0127] The plate 1308 is electrically conductive and may contact one or more portions of one or more of the switches.The plate 1308 is disposed on a plane that is horizontal to the plane of the switches.

[0128] Extension 1312 is formed on plate 1308 and extends away from plate 1308 (e.g., perpendicular (normal) to plate 1308). Extension 1312 can be made of a conductive material. When viewed from the top, as shown in the top view, extension 1312 forms channel 1316. Coolant flows through channel 1316 and flows between adjacent ones in extension 1312. When viewed from the top, channel 1316 and extension 1312 can be wavy, for example, as shown in the top view. Fig.13 Alternatively, the channel 1316 and the extension 1312 can have another suitable shape, including another waveform (eg, a full wave, a sawtooth wave, a square wave, etc.).

[0129] exist Figure 8 and Fig. 9 In the example of FIG. 5 , a coolant may flow between the plates and between the supports to cool the switch.

[0130] Fig.14 Various exemplary arrangements of switches of the inverter module 256 in the path of the coolant are shown. As shown in the upper left, the switches can be arranged so that the switches receive coolant one by one. As shown in the upper right, half of the switches can receive coolant flow in a first direction, while the other half of the switches can receive coolant flow in a second direction. In the upper right example, the switches receive coolant one by one.

[0131] The middle left example shows that the switches can be arranged to each receive coolant simultaneously. The middle right example shows that half of the switch can be arranged to simultaneously receive coolant flowing in a first direction, while the other half of the switch can be arranged to simultaneously receive coolant flowing in a second direction.

[0132] The lower left example shows that a group of two or more of the switches can be arranged to receive coolant simultaneously, wherein the groups receive coolant at different times. The lower right example shows that the switch can be placed near a center wall of a coolant channel, and coolant can flow toward the center wall.

[0133] Fig.15 A functional block diagram of an exemplary cooling system is included. The heat exchanger 1504 transfers heat away from (and cools) the coolant 1508 flowing through the switches 1512 of the inverter module 256. The coolant 1508 can be, for example, a liquid dielectric coolant or another suitable type of coolant. The heat exchanger 1504 can use a liquid 1516 and / or a gas (e.g., air 1520) to cool the coolant 1508.

[0134] The coolant 1508 may flow from the heat exchanger 1504 to one or more components 1516 or the electric motor 198. The coolant 1508 may then flow to the battery 199. The coolant 1508 may flow from the battery to one or more components 1516 or the electric motor 198. The coolant 1508 may then flow to the switch 1512 of the inverter module 256. The coolant may then flow to one or more components 1516 or the electric motor 198 before returning to the heat exchanger 1504.

[0135] Fig.16 1604 is a functional block diagram of an exemplary cooling system. When the pump 1604 is on, the pump 1604 pumps the coolant. The coolant control module 1608 controls whether the pump 1604 is on or off. The coolant control module 1608 can also control the speed of the pump 1604.

[0136] The pump 1604 pumps the coolant to the heater 1612. In some cases, the heater 1612 can be turned on to heat the coolant. The coolant control module 1608 can control whether the heater 1612 is turned on or off. The coolant output from the heater 1608 flows to the first valve 1616. When the first valve 1616 is in the first position (0), the first valve 1616 outputs the coolant to the first coolant path 1620. When the first valve 1616 is in the second position (1), the first valve 1616 outputs the coolant to the second coolant path 1624.

[0137] Although examples of switch branches are provided, the present application is also applicable to a single switch placed in the coolant.

[0138] The coolant in the first coolant path 1620 flows through a cooler 1628 before flowing to a second valve 1632. The cooler 1628 may be cooled using a heat exchanger 1636 of a heating, ventilation, and air conditioning (HVAC) system of the vehicle. The cooler 1628 cools the coolant flowing through the cooler 1628. The coolant in the second coolant path 1624 flows through a battery 199 and an inverter switch 1512 before flowing to the heat exchanger 1504. Although an example of an air-to-liquid heat exchanger is provided, as discussed above, the heat exchanger 1504 may be a liquid-to-liquid heat exchanger.

[0139] The second valve 1632 divides the coolant flow to the battery 199 and the third valve 1640. The third valve 1640 controls whether the coolant output from the second valve 1632 flows to the inverter switch 1512. The coolant control module 1608 can control the opening of the third valve 1640. The coolant output from the battery 199 can be lower than the temperature of the inverter switch 1512. Excess coolant can be stored in the tank 1644.

[0140] For a cold start of the vehicle, the coolant control module 1608 may turn on the heater 1612, actuate the first valve 1616 to the second (1) position, and close the third valve 1640. During normal operation, the coolant control module 1608 may turn off the heater 1612 or maintain the heater 1612 off, actuate the first valve 1616 to the second (1) position, and close the third valve 1640. For cooling (of the battery 199 and the inverter switch 1512), the coolant control module 1608 may turn off the heater 1612 or maintain the heater 1612 off, actuate the first valve 1616 to the first (0) position, and close the third valve 1640. To cool the inverter switch 1512 (rather than the battery 199 ), the coolant control module 1608 may turn off or maintain the heater 1612 off, actuate the first valve 1616 to the first (0) position, and open or vary the opening of the third valve 1640 .

[0141] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because other modifications will become apparent when studying the drawings, the specification and the following claims. It should be understood that one or more steps within the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each of the embodiments described above is described as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented as features of any one of the other embodiments and / or combined therewith, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the permutation of one or more embodiments with each other remains within the scope of the present disclosure.

[0142] Various terms (including "connected", "engaged", "coupled", "adjacent", "immediately adjacent", "on top of", "above", "below", and "placed") are used to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.). Unless explicitly described as "directly", when describing the relationship between a first and a second element in the above disclosure, the relationship can be a direct relationship in which there are no other intermediate elements between the first and second elements, but can also be an indirect relationship in which there are one or more intermediate elements (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be interpreted as meaning a logical (A or B or C) using a non-exclusive logical "or", and should not be interpreted as meaning "at least one of A, at least one of B, and at least one of C".

[0143] In the drawings, the direction of an arrow (as indicated by the arrow head) generally represents the flow of information (e.g., data or instructions) of interest to the illustration. For example, when element A and element B exchange various information, but the information transmitted from element A to element B is relevant to the illustration, an arrow may be directed from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. In addition, for information sent from element A to element B, element B may send a request for the information to element A or receive an acknowledgement of the information.

[0144] In this application (including the following definitions), the term "circuit" may be used in place of the term "module" or the term "controller". The term "module" may refer to, be part of, or include an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system on a chip.

[0145] The module may include one or more interface circuits. In some examples, the interface circuit may include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functions of any given module of the present disclosure may be distributed among multiple modules connected via interface circuits. For example, multiple modules may allow load balancing. In another example, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0146] The term code as used above may include software, firmware and / or microcode, and may refer to a program, a routine, a function, a class, a data structure and / or an object. The term shared processor circuit includes a single processor circuit that executes some or all of the code from multiple modules. The term group processor circuit includes a processor circuit that is combined with an additional processor circuit to execute some or all of the code from one or more modules. References to multiple processor circuits include multiple processor circuits on discrete chips, multiple processor circuits on a single chip, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit includes a single memory circuit that stores some or all of the code from multiple modules. The term group memory circuit includes a memory circuit that is combined with additional memory to store some or all of the code from one or more modules.

[0147] The term memory circuit is a subset of the term computer-readable medium. The term computer-readable medium as used herein does not include transient electrical or electromagnetic signals propagated through a medium (e.g., on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (e.g., flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (e.g., static random access memory circuits or dynamic random access memory circuits), magnetic storage media (e.g., analog or digital tapes or hard drives), and optical storage media (e.g., CDs, DVDs, or Blu-ray discs).

[0148] The apparatus and method described in this application can be partially or completely implemented by a special-purpose computer formed by configuring a general-purpose computer to perform one or more specific functions implemented by a computer program. The functional blocks, flow chart components and other elements described above serve as software specifications, which can be converted into computer programs by routine work of technicians or programmers.

[0149] The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include or rely on stored data. The computer program may include a basic input / output system (BIOS) that interacts with the hardware of the special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0150] The computer program may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language) or JSON (JavaScript Object Notation), (ii) assembly code, (iii) target code generated by a compiler from a source code, (iv) source code executed by an interpreter, (v) source code compiled and executed by a just-in-time compiler, etc. By way of example only, the source code may be written using the syntax of a language including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language, Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

Claims

1. A switch cooling system, comprising: Coolant channels; A switch of an inverter module, the switch being disposed in the coolant channel, configured to be immersed in the coolant in the coolant channel, and comprising: a first terminal disposed on a first plane and configured to be connected to a direct current (DC) reference potential; a second terminal disposed on the second plane and configured to be connected to an alternating current (AC) reference potential; a gate, an emitter and a collector, wherein the gate, the emitter and the collector are disposed between the first and second planes; a first cooling feature extending away from the first and second planes, directly contacting the first terminal, and configured to allow coolant to flow therethrough; and A second cooling feature extends away from the first cooling feature, the first plane, and the second plane, directly contacts the second terminal, and is configured to allow coolant to flow therethrough.

2. The switch cooling system according to claim 1, wherein: The first and second planes are parallel.

3. The switch cooling system according to claim 1, wherein: The first cooling feature extends perpendicularly away from the first and second planes.

4. The switch cooling system according to claim 1, wherein: The second cooling feature extends perpendicularly away from the first and second planes.

5. The switch cooling system according to claim 1, further comprising a second switch of the inverter module, the second switch being disposed in the coolant channel, configured to be immersed in the coolant in the coolant channel, and comprising: a third terminal disposed on a third plane and configured to be connected to a second DC reference potential; a second gate, a second emitter, and a second collector, wherein the second gate, the second emitter, and the second collector are disposed between the second and third planes; as well as A third cooling feature extends away from the second and third planes, directly contacts the third terminal, and is configured to allow coolant to flow therethrough.

6. The switch cooling system of claim 5, further comprising an electrical insulator disposed between (a) the gate, the emitter, and the collector and (b) the second gate, the second emitter, and the second collector.

7. The switch cooling system of claim 5, further comprising first, second, and third electrical conductors electrically connected to the first, second, and third terminals and extending through the coolant passage to an outside of the coolant passage.

8. The switch cooling system according to claim 1, wherein: The first cooling feature includes a member extending perpendicular to the first and second planes.

9. The switch cooling system according to claim 1, wherein: The first cooling feature includes: a plurality of parallel plates; and Supports that separate the plates from each other.

10. The switch cooling system according to claim 9, wherein: The struts extend perpendicular to the parallel plates.

11. The switch cooling system according to claim 9, wherein: The support column is cylindrical.

12. The switch cooling system according to claim 11, wherein: The struts all have the same diameter.

13. The switch cooling system according to claim 11, wherein: The struts all have the same pitch.

14. The switch cooling system according to claim 11, wherein: The struts include a first strut having a first diameter and a second strut having a second diameter.

15. The switch cooling system according to claim 14, wherein: The first struts have a first pitch and the second struts have a second pitch, wherein the first pitch is different than the second pitch.

16. The switch cooling system according to claim 1, wherein: The first cooling feature includes: a first layer comprising an inlet, an outlet, a first portion fluidly connected to the inlet, and a second portion fluidly connected to the outlet; a second layer comprising a third portion fluidly connected to the first and second portions of the first layer; and A third layer includes a fourth portion fluidly connected to the first and second portions.

17. The switch cooling system according to claim 1, wherein: The first cooling feature includes: two parallel plates; and A helical member has a first rotational direction and is disposed between the two parallel plates.

18. The switch cooling system according to claim 17, wherein: The first cooling feature further comprises: A second helical member has a second direction of rotation and is disposed between the two parallel plates.

19. The switch cooling system according to claim 18, wherein: The second rotational direction is different from the first rotational direction.

20. The switch cooling system according to claim 1, wherein: The first cooling feature includes: a first material having uniform openings configured to allow coolant to flow therethrough; and A second material having non-uniform openings configured to allow coolant to flow therethrough.

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