A new energy vehicle silicon nitride power module for multi-system cooperative simulation

Abstract

The application discloses a new energy automobile silicon nitride power module for multi-system cooperative simulation, which comprises a heat dissipation base, the top of the heat dissipation base is fixedly connected with a flexible substrate, the top of the flexible substrate is fixedly connected with a three-generation semiconductor power control module, one side of the three-generation semiconductor power control module is connected with a battery control module, and the surface of the three-generation semiconductor power control module is connected with a battery module and a power management module. The new energy automobile silicon nitride power module for multi-system cooperative simulation is characterized in that: step S1 is used for designing and simulating the new energy automobile power module; step S2 is used for developing a process of a flexible substrate capable of multi-element integrated power batteries; and step S3 is used for developing corresponding based on the three-generation semiconductor power control module, so that the problems of large current fluctuation, high failure rate and poor safety of automobile lines due to the multi-wire bundle current transmission mode, the complicated assembly of the artificial separation type assembly process and the long time consumption are solved.

Description

Technical Field

[0001] This invention relates to the field of power module technology, specifically to a silicon nitride power module for new energy vehicles with multi-system collaborative simulation. Background Technology

[0002] In new energy vehicles, the power module is the core component for charging and energy conversion. Its function is to convert AC to DC and also to convert voltage levels. For example, when the car is charged externally, the AC power is converted to DC by the power module before being supplied to the battery, while simultaneously converting the charging voltage to an appropriate voltage for charging the battery pack. When the battery discharges, the power module converts the DC power back to AC power for the AC motor and enables frequency conversion control of the AC motor. The performance of the power module directly affects the power release speed and charging performance of the electric vehicle. As a core component of the motor control system and battery control system of new energy vehicles, its market demand is increasing with strong government support for new energy vehicles. However, its shortcomings, such as slow transmission speed, limited functionality, and high power consumption, are becoming increasingly apparent. Third-generation semiconductor materials, as a high-performance alternative, are beginning to emerge. Their characteristics of high power, radiation resistance, strong conductivity, high voltage and high temperature resistance, fast operating speed, and low loss have gained industry favor and are triggering an industry revolution.

[0003] The rapid development of new energy vehicles in recent years has led to the integration of numerous electronic components in automotive electronics, which has placed higher demands on automotive circuits, power management, and control. Traditional automotive circuits, due to their use of multi-wire harness current transmission, suffer from large current fluctuations, high failure rates, and poor safety. They also employ manual, separate assembly processes, which are complex and time-consuming. Furthermore, their shortcomings, such as slow transmission speed, limited functionality, high power consumption, and low integration, are becoming increasingly apparent. The industry urgently needs new energy vehicle power modules that are highly integrated, high-power, lightweight, and easy to assemble. Summary of the Invention

[0004] The purpose of this invention is to provide a silicon nitride power module for new energy vehicles with multi-system collaborative simulation, in order to solve the problems mentioned in the background art, such as large current fluctuations, high failure rate, poor safety, large current transmission method, large current transmission speed, large failure rate, large power consumption and low integration of traditional automotive circuits, which adopt multi-wire harness current transmission method, complex assembly process, long time consumption, slow transmission speed, single function, high power consumption and low integration.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a silicon nitride power module for new energy vehicles with multi-system collaborative simulation, including a heat dissipation base, a flexible substrate fixedly connected to the top of the heat dissipation base, a third-generation semiconductor power control module fixedly connected to the top of the flexible substrate, a battery control module connected to one side of the third-generation semiconductor power control module, and a battery module and a power management module connected to the surface of the third-generation semiconductor power control module.

[0006] Preferably, the flexible substrate includes a silicon carbide substrate, a high-voltage busbar, a low-voltage acquisition board, and an insulating PET film.

[0007] Preferably, the silicon carbide substrate includes a first copper layer, a silicon nitride layer, a second copper layer, and a silver layer, and the first copper layer, silicon nitride layer, second copper layer, and silver layer are connected sequentially from bottom to top.

[0008] Preferably, the bottom of the heat dissipation base is connected to a plurality of heat dissipation fins.

[0009] A method for fabricating a silicon nitride power module for new energy vehicles based on multi-system co-simulation includes:

[0010] Step S1: Design and simulate the power module for new energy vehicles;

[0011] (1) Design a flexible substrate for multi-functional integrated power batteries;

[0012] (2) Design and simulation based on the third-generation semiconductor power control module.

[0013] Step S2: Develop a process for integrating flexible substrates for power batteries into multiple components;

[0014] (1) Develop high-precision line etching technology;

[0015] (2) Develop self-fusing technology for flexible substrates for multi-element integrated power batteries.

[0016] Step S3: Develop corresponding power control modules based on third-generation semiconductors;

[0017] (1) High-temperature lamination assembly of power module CCS by high-temperature and high-pressure lamination assembly process;

[0018] (2) Develop intelligent production lines to achieve mass production of power module CCS;

[0019] (3) Conduct insulation, withstand voltage and aging resistance tests on the power module.

[0020] Preferably, in step S3, the high-temperature and high-pressure lamination assembly process includes a multi-layer structure special mold for power module CCS lamination and equipment parameters suitable for power module CCS lamination.

[0021] Preferably, the multi-layer structure special mold includes a high-strength upper base, a high-strength middle base, a high-strength lower base, and a molding chamber.

[0022] Preferably, the equipment parameters include three variable parameters: temperature, pressure, and time.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] 1. By replacing traditional power electronic components with third-generation semiconductor power control modules, the characteristics of high temperature and high pressure resistance, low thermal resistance and low loss are utilized to solve the temperature and pressure resistance problems of power modules, reduce the space of battery control modules, increase battery capacity, and improve the control feedback speed and accuracy of battery control modules.

[0025] 2. By using a flexible substrate for multi-integrated power batteries, the signal analysis function module is separated from the battery control module and integrated into the third-generation semiconductor power control module. Signal acquisition and analysis are completed near the acquisition point, shortening the transmission distance, reducing transmission loss and interference, and improving the accuracy of control signals, thereby improving the accuracy and safety of battery control.

[0026] 3. Through multiphysics simulation technology, the electrical, mechanical, and thermal physical parameters of the power module are simulated and designed, and an accurate database and product model of the corresponding materials are established to guide the design and production, improve efficiency, and ensure product quality.

[0027] 4. Since the power module integrates a lot of electronic components, and it is necessary to perform three-dimensional structural molding according to the requirements of the power module structure of the power battery to avoid damage to the components, we innovatively use multi-layer structure special mold assisted pressing technology to solve the problems of different product molding structure requirements and heat uniformity.

[0028] 5. Through diversified design solutions, the problem of electromagnetic interference caused by the simultaneous integration of high-voltage and low-voltage systems in the battery control module is solved by adopting an isolation method, thus realizing the product design of electromagnetic compatibility between high-voltage and low-voltage signals. Attached Figure Description

[0029] Figure 1 This is a side view of the present invention;

[0030] Figure 2 This is a schematic diagram of the present invention;

[0031] Figure 3 This is a cross-sectional view of the flexible substrate of the present invention;

[0032] Figure 4 This is a design drawing of the flexible substrate of the present invention;

[0033] Figure 5 This is a schematic diagram of the vacuum etching principle of the present invention;

[0034] Figure 6 This is a schematic diagram of the self-fusing fuse of the present invention;

[0035] Figure 7 This is a schematic diagram of the multi-layer mold structure of the present invention.

[0036] In the figure: 1. Heat dissipation base; 2. Flexible substrate 2; 3. Third-generation semiconductor power control module; 4. Battery module; 5. Power management module; 6. Battery control module; 7. First copper layer; 8. Silicon nitride layer; 9. Second copper layer; 10. Metallic silver layer; 11. Heat dissipation fins. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Please see Figure 1-7 The present invention provides a silicon nitride power module for new energy vehicles with multi-system collaborative simulation, including a heat dissipation base 1, a flexible substrate 2 fixedly connected to the top of the heat dissipation base 1, a third-generation semiconductor power control module 3 fixedly connected to the top of the flexible substrate 2, a battery control module 6 connected to one side of the third-generation semiconductor power control module 3, and a battery module 4 and a power management module 5 connected to the surface of the third-generation semiconductor power control module 3.

[0039] In use, the flexible substrate 2 includes a silicon carbide substrate, a high-voltage bus, a low-voltage acquisition board, and an insulating PET film; the silicon carbide substrate includes a first copper layer 7, a silicon nitride layer 8, a second copper layer 9, and a metallic silver layer 10, and the first copper layer 7, the silicon nitride layer 8, the second copper layer 9, and the metallic silver layer 10 are connected sequentially from bottom to top; a number of heat dissipation fins 11 are connected to the bottom of the heat dissipation base 1.

[0040] A method for fabricating a silicon nitride power module for new energy vehicles based on multi-system co-simulation includes:

[0041] Step S1: Design and simulate the power module for new energy vehicles;

[0042] (1) Design of a flexible substrate for multi-element integrated power batteries 2;

[0043] (2) Based on the third-generation semiconductor power control module 3, the corresponding design and simulation are carried out.

[0044] Step S2: Develop the process for the flexible substrate 2 of power batteries that can be integrated into multiple components;

[0045] (1) Develop high-precision line etching technology;

[0046] (2) Develop self-melting technology for flexible substrate 2 of power battery that can be integrated into multiple components.

[0047] Step S3: Develop the corresponding system based on the third-generation semiconductor power control module 3;

[0048] (1) High-temperature lamination assembly of power module CCS by high-temperature and high-pressure lamination assembly process;

[0049] (2) Develop intelligent production lines to achieve mass production of power module CCS;

[0050] (3) Conduct insulation, withstand voltage and aging resistance tests on the power module.

[0051] In use, step S3, the high temperature and high pressure lamination assembly process includes a multi-layer structure special mold for power module CCS lamination and equipment parameters suitable for power module CCS lamination; the multi-layer structure special mold includes a high-strength upper base, a high-strength middle base, a high-strength lower base and a molding chamber; the equipment parameters include three variable parameters: temperature, pressure and time.

[0052] Example 1

[0053] Please see Figure 1-7 In this embodiment, when in use:

[0054] Step S1: Design and simulate the power module for new energy vehicles;

[0055] (1) Design of a flexible substrate for multi-element integrated power batteries 2;

[0056] Through simulation and design, a flexible substrate 2 for multi-functional integrated power batteries was designed, and a power module that can integrate multiple devices such as flexible substrate, high voltage transmission system and power management system was developed.

[0057] (2) Design and simulation based on the third-generation semiconductor power control module 3;

[0058] By utilizing multiphysics simulation, we analyze the thermal effects and corresponding deformations generated by current, simulate the high-current fuse circuit of the power module, and simulate the current distribution, heating and stress deformation on the power bus to obtain accurate data, establish the company's design and simulation database, form a complete module solution, guide the design and on-site production, and avoid overheating, adverse stress deformation and product failure.

[0059] Step S2: Develop the process for the flexible substrate 2 of power batteries that can be integrated into multiple components;

[0060] (1) Develop high-precision line etching technology;

[0061] Based on vacuum etching machines, vacuum etching and two-fluid etching control technologies have been developed. Vacuum etching machines employ a two-sided vacuum adsorption method to rapidly absorb the etching solution on the board surface, allowing fresh solution to quickly reach the board surface. This ensures consistent etching rates at the top and bottom of the circuit, reducing burr formation, increasing the etching factor, and improving circuit smoothness. The principle involves adding a solution recovery system to the upper spray surface of existing horizontal ordinary etching lines. During etching, the solution recovery system absorbs the etching solution sprayed onto the board surface, preventing residue and effectively improving etching uniformity. This results in improved overall linewidth uniformity and a higher etching factor. Two-fluid etching works by modifying the spray system of existing horizontal ordinary etching lines, achieving a combination of two or more heterogeneous components. The etching solution combines with air in the etching spray system, resulting in smaller sprayed liquid particles that more easily penetrate narrow gaps.

[0062] (2) Develop self-fusing technology for flexible substrate 2 of power battery that can be integrated into multiple components;

[0063] Each low-voltage acquisition line harness on the low-voltage acquisition board integrates a copper-based fuse. When the current through the low-voltage acquisition line is too large, the temperature will accumulate and rise at the copper-based fuse. When the temperature reaches the melting point of copper, it can melt and cut off the circuit first, thereby disconnecting the low-voltage acquisition line and preventing the low-voltage acquisition line harness from catching fire or burning. This ensures the safety of the low-voltage acquisition line harness and improves the safety and stability of the power battery.

[0064] Step S3: Develop the corresponding power control module (3) based on the third-generation semiconductor;

[0065] (1) High-temperature lamination assembly of power module CCS by high-temperature and high-pressure lamination assembly process;

[0066] The high-voltage busbar, low-voltage acquisition board, and insulating PET film are positioned and molded using a positioning substrate and then assembled into a whole by heating and pressurizing. The mold needs to avoid the power electronic components on the product to ensure both the pressing strength and the protection of the product components.

[0067] (2) Develop intelligent production lines to achieve mass production of power module CCS;

[0068] Construct a production line that can fully or semi-automate lamination, acquisition and welding, electrical testing, and functional testing, enabling mass production of power module CCS.

[0069] (3) Conduct insulation, withstand voltage and aging resistance tests on the power module;

[0070] The power module is tested for insulation, withstand voltage, and aging resistance using testing equipment.

[0071] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing a new energy vehicle silicon nitride power module through multi-system collaborative simulation, characterized in that, The application relates to a new energy automobile silicon nitride power module. The preparation method comprises the following steps: Step S1: designing and simulating the new energy automobile power module, specifically comprising: S11, designing the flexible substrate (2) capable of integrating multiple power batteries; S12, designing and simulating the third-generation semiconductor power control module (3); Step S2: developing the process of the flexible substrate (2) capable of integrating multiple power batteries, specifically comprising: S21, developing a high-precision line etching process technology; S22, developing a self-fusing technology for the flexible substrate (2) capable of integrating multiple power batteries; Step S3: developing the third-generation semiconductor power control module (3), specifically comprising: S31, high-temperature laminating assembly of the power module CCS through a high-temperature and high-pressure laminating assembly process; S32, developing an intelligent production line to realize batch production of the power module CCS; S33, insulating, voltage-resistant and aging-resistant tests of the power module. The S11, designing the flexible substrate (2) capable of integrating multiple power batteries, specifically comprises:

2. The method according to claim 1, wherein the method is characterized in that, Through simulation and design, the flexible substrate (2) capable of integrating multiple power batteries is designed, and a power module integrating multiple devices such as a flexible substrate, a high-voltage transmission system and a power management system is developed; The S12, designing and simulating the third-generation semiconductor power control module (3), specifically comprises: Through multi-physical field simulation, the thermal effect and corresponding deformation caused by the current are analyzed, the power module large-current fuse line is simulated, the current distribution, heating and stress deformation on the power bus are simulated, accurate data are obtained, a design and simulation database of the company is established, a completed module scheme is formed, design and on-site production are guided, overheating, bad stress deformation and product failure are avoided. The S21, developing a high-precision line etching process technology, specifically comprises:

3. The method for fabricating a silicon nitride power module for new energy vehicles based on multi-system collaborative simulation according to claim 1, characterized in that, ​ Based on the vacuum etching machine, the vacuum etching and two-fluid etching control technology are developed. The vacuum etching machine adopts the vacuum adsorption method on both sides to quickly adsorb the liquid on the board surface. The new liquid quickly reaches the board surface, so that the etching rate of the top and bottom of the line is consistent, the formation of line burrs is reduced, the etching factor is improved, and the smoothness of the line is improved. The principle is to increase the liquid recovery system on the upper spray surface on the basis of the existing horizontal ordinary etching line. The liquid recovery system absorbs the liquid sprayed on the board surface during etching, avoids the residue of the liquid on the upper board, effectively improves the etching uniformity, and relatively improves the overall line width uniformity, so as to achieve a high etching factor. The working principle of two-fluid etching is to change the spray system on the basis of the existing horizontal ordinary etching line, that is, to achieve the purpose of combining two or more heterogeneous combinations into one. The etching liquid is combined with air in the etching spray system, so that the liquid particles sprayed out are smaller and more easily enter narrow spaces. The S22 develops a self-fusing technology for a flexible substrate (2) of a multi-element integrated power battery, specifically including: The low-voltage acquisition board is integrated with a copper-based fuse on each low-voltage acquisition wire harness. When the low-voltage acquisition wire passes through a large current, the copper-based fuse part will gather and heat up. When the temperature reaches the melting point of copper, the circuit is first fused and cut off, thereby disconnecting the low-voltage acquisition wire, avoiding the low-voltage acquisition wire harness from catching fire or burning out, ensuring the safety of the low-voltage acquisition wire harness, and improving the safety and stability of the power battery.

4. The preparation method of a multi-system coordinated simulation silicon nitride power module of a new energy vehicle according to claim 1, characterized in that, The S31 performs high-temperature lamination assembly of the power module CCS through a high-temperature high-pressure lamination assembly process, specifically including: The high-temperature high-pressure lamination assembly process includes a special mold for the multi-layer structure of the power module CCS and equipment parameters suitable for the lamination of the power module CCS. The special mold for the multi-layer structure includes a high-strength upper base, a high-strength middle base, a high-strength lower base, and a forming chamber. The equipment parameters include three variable parameters of temperature, pressure, and time. The high-voltage bus bar, low-voltage acquisition board, and insulation coating PET film are positioned and assembled into a whole by heating and pressing after positioning and assembling on the positioning base. The mold needs to avoid the power electronic components on the product, ensuring the pressing strength and the product components are not damaged. The S32 develops an intelligent production line to realize batch production of the power module CCS, specifically including: A production line capable of realizing complete automation or semi-automation of lamination, acquisition welding, electrical testing, and functional testing is constructed. The production line can realize batch production of the power module CCS. The S33 performs insulation, voltage resistance, and aging resistance tests on the power module, specifically including: The insulation, voltage resistance, and aging resistance tests are performed on the power module by a test detection device.

Images