power module

Abstract

The invention relates to a power module (10) having at least one cooling body (8), at least one power unit (11) comprising at least one semiconductor element (6) and a base plate (7), a device (1) for enclosing the power unit at least partially configured within and / or on the cooling body and for centering a control unit (20) relative to the power unit, the device comprising a frame (2) at least partially, preferably completely, surrounding the base plate, at least one first protruding section (3) engaging into a recess or opening (12) of the cooling body, at least one second protruding section (4) configured for engaging into a recess or opening or notch (21) of the control unit having at least one electronic (24), the profile of the second protruding section being at least substantially configured in the shape of a star having at least a first leg, a second leg and a third leg, when viewed in cross section.

Description

Technical Field

[0001] The present invention relates to a power module having at least one cooling body and at least one power unit, wherein the power unit includes at least one semiconductor element and a substrate. Background Technology

[0002] Precise alignment of the power unit with the drive and control unit, especially the circuit board, is difficult. Inaccuracy results in pins not being properly positioned, which in turn prevents or at least prevents the power module from fully performing its functions. Summary of the Invention

[0003] The basic objective of this invention is to simplify and improve the positioning of the drive control unit relative to the power unit.

[0004] This objective is achieved through a power module that has:

[0005] -At least one cooling element;

[0006] - At least one power unit, wherein the power unit includes at least one semiconductor element and a substrate;

[0007] - A means for surrounding a power unit at least partially constructed within and / or above a cooling body and for centering a drive control unit relative to the power unit, wherein the means comprises:

[0008] - A frame, wherein the frame at least partially, preferably completely, surrounds the substrate;

[0009] - At least one first protruding section, wherein the first protruding section engages in a groove or opening of the cooling body;

[0010] - At least one second protruding section, wherein the second protruding section is configured to engage with a groove, opening, or notch in a drive control unit having at least one electronic device.

[0011] The outline of the second protruding segment, when viewed in cross-section, is at least substantially constructed in the shape of a star, wherein the star has at least one first leg, a second leg, and a third leg.

[0012] An advantageous embodiment is that the outline of the first protruding segment is at least substantially circular when viewed in cross-section. However, the outline of the first protruding segment can also be, for example, a star or a cross shape. Other shapes are also contemplated.

[0013] The device is preferably a one-piece unit.

[0014] The substrate is advantageously used as a guiding element.

[0015] The substrate includes, for example, at least one conductive layer, wherein the conductive layer preferably has copper, and at least one thermally conductive layer, wherein the thermally conductive layer preferably has ceramic.

[0016] The thermally conductive layer is advantageously electrically insulating. It should both provide insulation and dissipate waste heat. Ceramic is advantageous here because it provides particularly good electrical insulation.

[0017] The substrate advantageously has three layers. The first layer facing the cooling body preferably has copper. The second layer adjacent to the first layer preferably has ceramic. The third layer adjacent to the second layer preferably has copper. The first and third layers are therefore conductive layers, while the second layer is therefore a thermally conductive layer. The thermally conductive layer is advantageously electrically insulating.

[0018] The guiding element preferably includes at least one semiconductor element at and / or on the third layer, and preferably includes multiple semiconductor elements.

[0019] The power unit is preferably part of a converter system or a power conversion system.

[0020] This device replaces the existing housing and is significantly simplified in terms of structure. Furthermore, the present invention allows for a reduction in structural dimensions while ensuring sufficient and uniform cooling.

[0021] A star-shaped profile can also be considered a Y-shaped profile.

[0022] The three legs are particularly advantageous because they ensure high stability with minimal material usage. Material usage is significantly reduced compared to the exemplary second protrusion, which is constructed as a roof, cone, or column.

[0023] To withstand high temperatures, it is advantageous to use plastics or resins with a high glass fiber content, which is very expensive. Here, even a small reduction in material reduces costs.

[0024] This profile also offers the advantage that no reinforcement is needed for stabilization, which would otherwise be necessary, especially for material shrinkage during the cooling of cast or injection molded frames.

[0025] The second protruding section is reinforced with a star-shaped outline, especially in the direction towards the drive and control unit. This makes the second protruding section particularly stable and less prone to tilting. Tilting should be avoided, as it can lead to defects during the assembly of the power module and drive and control unit.

[0026] The star-shaped profile is also advantageous in terms of tooling costs. For example, in the second protruding section constructed as a hollow cylinder, a pin is required for tooling, around which the injection-molded material is placed. Due to the star shape, this pin can be eliminated.

[0027] The star-shaped profile reduces the contact area between the second protruding section and the drive unit, thereby reducing friction during engagement. Compared to a circle, the engagement process is smoother if only the three star-shaped tips (i.e., the ends of the radially viewed legs) contact the drive unit.

[0028] One advantageous implementation proposes that the first leg and the second leg are arranged such that they partially surround the outline of the first segment when viewed from a bird's-eye view.

[0029] This is a particularly space-saving implementation method.

[0030] One advantageous implementation proposes that the length of the first leg corresponds to the length of the second leg.

[0031] One particularly advantageous implementation proposes that all legs are of the same length. Therefore, the protruding sections are especially stable.

[0032] An advantageous implementation also proposes that the first leg is longer than the third leg.

[0033] This implementation can also be used for space-saving designs. In this case, the shortest leg is advantageously positioned away from the other segment.

[0034] One advantageous implementation proposes that the frame be fixed to the cooling body by means of adhesive bonding.

[0035] Since spiral connections and other methods are not required, the cooling element, especially the cooling element base, can be constructed to be more slender. Therefore, a compact design for the power module can also be achieved.

[0036] One advantageous embodiment proposes that the frame is constructed in the shape of a rectangle, wherein a first protruding section is provided at least substantially at the corners of the frame, particularly the outer corners, and wherein a second protruding section is provided at least substantially at the corners of the frame, particularly the outer corners.

[0037] Therefore, it can achieve positioning or centering very well.

[0038] One advantageous embodiment proposes that the first protruding segment and the second protruding segment are configured to extend in opposite directions.

[0039] Therefore, good positioning of the frame relative to the cooling body can be achieved, as well as good positioning of the drive control unit relative to the frame.

[0040] One advantageous embodiment proposes that the first protruding section and the second protruding section are oriented perpendicular to the surface of the cooling body.

[0041] Therefore, the joining process is achieved particularly well.

[0042] One advantageous embodiment proposes that the frame has polyphenylene sulfide (PPS).

[0043] PPS is advantageous because it is a thermoplastic material that is resistant to high temperatures (e.g., it does not release heat until 175°C).

[0044] One advantageous embodiment proposes that the frame has a polyphenylene sulfide with a fiber share of 50% to 75%, particularly 60% to 65%.

[0045] However, synthetic plastics can also be used.

[0046] One advantageous implementation proposes that the angle between the first leg and the second leg is equal to the angle between the second leg and the third leg.

[0047] A particularly advantageous feature is the star-shaped legs with a uniform 120° offset. This specific shape allows for better compensation of shape and position tolerances during the positioning process. With the same initial aperture in the circuit board, the entire power module experiences greater torsion.

[0048] One advantageous embodiment proposes that the width of the leg is between 0.5 mm and 2 mm, preferably between 0.8 mm and 1.6 mm, and particularly between 1.1 mm and 1.3 mm.

[0049] For stability reasons, 1.2mm is a good fit.

[0050] One advantageous implementation proposes that the power module also has a fixing element for fixing the drive control unit.

[0051] Therefore, the drive unit can be securely fixed. The fixing element is, for example, a screw (see also the attached diagram).

[0052] The solution to this objective is also achieved through a framework for a power module described in one of the foregoing technical solutions, the framework having:

[0053] - At least one first protruding section, wherein the first protruding section is configured to engage with a groove or opening in the cooling body;

[0054] - At least one second protruding segment, wherein the second protruding segment is configured to engage with a groove or opening in a drive unit having at least one electronic device, wherein the outline of the second protruding segment, when viewed in cross-section, is at least substantially configured in the shape of a star, wherein the star has at least three legs.

[0055] One advantageous embodiment proposes that, when viewed in cross-section, the outline of the first protruding segment (3) is at least substantially circular in shape (in other words: circular).

[0056] The solution to this objective is also achieved through a power converter that has:

[0057] -This power module,

[0058] -A drive and control unit having at least one electronic component

[0059] The power module and the drive control unit are interconnected.

[0060] Here, an advantageous embodiment proposes that the drive control unit is centered relative to the power module by engaging a second protruding section of the power module into a groove or opening in the drive control unit. Attached Figure Description

[0061] The invention will now be described and explained in more detail with reference to the embodiments shown in the accompanying drawings. The drawings show:

[0062] Figure 1 This illustrates a feasible design scheme for the power module.

[0063] Figure 2 and Figure 9 The outline of the second protruding segment is shown in detail.

[0064] Figure 3 Show Figure 1 Exploded view of feasible design schemes in the diagram.

[0065] Figure 4 and Figure 5 The power module connected to the drive control unit is shown.

[0066] Figure 6 The power converter is shown.

[0067] Figure 7 The aerial view shows the power module connected to the drive control unit.

[0068] Figure 8 The frame is shown. Detailed Implementation

[0069] Figure 1 A feasible design scheme for a power module 10 having device 1 is shown.

[0070] Figure 3 Show Figure 1 An exploded view of the feasible design schemes.

[0071] Device 1 surrounds power unit 11 constructed on power module 10.

[0072] The power unit 11 includes at least one semiconductor element 6. The semiconductor element is, in particular, a power semiconductor, such as an IGBT. The power unit 11 also includes a substrate 7.

[0073] The device 1 includes a frame 2, which completely surrounds the substrate 7.

[0074] The device 1 includes at least one first protrusion 3, wherein the first protrusion 3 engages in a groove or opening 12 of the cooling body 8 (in the figures) or is configured to engage in the opening 12.

[0075] The opening 12 can be, for example, a notch, a groove, a blind hole, or a hole.

[0076] The opening 12 is advantageously constructed in the base 22 (or substrate) of the cooling body 8.

[0077] In the attached figure, cooling fins 81 are disposed below the substrate 22.

[0078] The cooling body 8, as shown in the accompanying drawings, has a plurality of cooling fins 81. The cooling fins 81 are advantageously arranged in parallel.

[0079] The device 1 also includes at least one second protrusion 4, wherein the second protrusion 4 is configured for engagement with a drive unit 20 having at least one electronic device (see [link]). Figure 4 ) a notch 21 or a groove or opening (see Figure 4 For example, in the hole.

[0080] The drive control unit 20 is advantageously the main circuit board.

[0081] The accompanying drawings also show contact elements 9. The contact elements are preferably pins. The power unit 11 advantageously has multiple contact elements 9. The contact elements 9 can be configured as a single pin or as a multi-pin system.

[0082] The device 1 has a fixing element 5 in the attached drawing. The fixing element 5 is configured to fix the drive control unit 20.

[0083] Frame 2 is constructed as a rectangle in the attached drawing. However, other shapes are also possible, such as circular frames, elliptical frames, square frames, or trapezoidal frames.

[0084] Figure 1 and Figure 3 As shown: the first protruding segment 3 is at least substantially located at the outer corner of the frame 2 or in the area of ​​the outer corner of the frame.

[0085] Figure 1 and Figure 3 It is also shown that the second protruding segment 4 is at least substantially located at the outer corner of the frame 2 or in the area of ​​the outer corner.

[0086] Alternatively, you could consider setting them diagonally opposite each other.

[0087] Two segments 3 and 4 are advantageously positioned at a common corner of frame 2. The two segments 3 and 4 are advantageously connected to each other by a material fit. Therefore, these segments are advantageously configured to extend in opposite directions. These segments are advantageously one-piece.

[0088] The first protruding section 3 is advantageously constructed as a positioning bolt.

[0089] In this way, device 1 can be precisely positioned on the surface of cooling body 8. Advantageously, there is no form-fitting and / or force-fitting connection here.

[0090] The frame 2 is fixed to the cooling body 8, for example, by means of adhesive bonding.

[0091] The first type of protrusion 3 advantageously has a shape that engages at least substantially precisely with the groove or opening 12 of the cooling body 8.

[0092] The first protruding segment 3 advantageously has a circular cross-section. However, other shapes may also be considered.

[0093] The protruding section 4 is advantageously constructed as a centering top.

[0094] The outline of the second protruding segment 4, when viewed in cross-section, is at least substantially constructed in the shape of a star, wherein the star has at least one first leg, a second leg, and a third leg.

[0095] This achieves precise centering of the control unit. No boot tools are required.

[0096] The outlines of sections 3 and 4 are in Figure 2 and Figure 9 It is shown in detail in the text.

[0097] The second protruding segment 4 advantageously has exactly three legs S1, S2 and S3. These legs are arranged in a star shape (or Y shape) around the midpoint M.

[0098] Regarding the midpoint M, it is advantageous to propose that l1 = l2 = l3, where l1 is the length of the first leg S1, l2 is the length of the second leg S2, and l3 is the length of the third leg S3.

[0099] For values ​​below l1, it is advantageous to propose: 0.5mm ≤ l1 ≤ 5mm. Particularly preferred is: 1.5mm ≤ l1 ≤ 3.5mm.

[0100] A particularly advantageous implementation is: 2mm ≤ l1 ≤ 3mm, for example, l1 is 2.515mm.

[0101] Alternatively, one could consider having one leg that is longer than the other.

[0102] Legs S1, S2 and S3 are advantageously configured such that for angles α, β and γ located between them, α = β = γ applies.

[0103] The leg width b2 at leg S2 is shown as an example. The leg width is advantageously between 0.5 mm and 2 mm, preferably between 0.8 mm and 1.6 mm, and particularly between 1.1 mm and 1.3 mm.

[0104] For stability reasons, 1.2mm is a good fit.

[0105] Figure 2 As shown: the protruding segment 4 engages with the lateral notch of the cover 14.

[0106] The settings described in sections 3 and 4 prevent torsion.

[0107] In addition, Figure 2 As shown: Cover 14 has pins (see Figure 14) Figure 1 ) opening 91.

[0108] The frame 2 is advantageously configured such that the applied potting compound is retained within the area bounded by the frame 2 and the power module 10 or the side of the power module 10.

[0109] For this purpose, the frame 2 is advantageously connected to the surface of the power module 10 by means of material bonding, particularly by means of adhesive bonding.

[0110] Silicone resins are particularly well-suited as potting compounds. Polyurethanes and / or epoxides may also be considered.

[0111] Silicone resin is heat-resistant. Furthermore, silicone resin can be cured at room temperature or by means of UV (ultraviolet) light.

[0112] In addition, silicone resins have excellent electrical insulation properties, as well as low viscosity and good flow properties.

[0113] The power unit 11 is advantageously connected to the cooling body 8. This connection is preferably achieved by means of pressing and / or brazing and / or sintering. However, other types of connections are also conceivable, particularly connections using other thermally conductive materials.

[0114] In addition, connections achieved by inputting heat, such as through welding, are also feasible.

[0115] The power unit 11 is advantageously configured as part of the module’s own cooling system.

[0116] The power unit is advantageously constructed as a direct copper bond (also known as DCB).

[0117] The module's own cooling body advantageously incorporates a power unit 11 and contact elements.

[0118] The cooling body 8 advantageously has at least one power unit 11. However, the cooling body 8 may also include two or more power units 11.

[0119] The optimal solution is that the cooling unit 8 includes three power units 11. This ensures good cooling in terms of power under optimized load conditions.

[0120] Three power units 11 are advantageous because each power unit can be associated with one of the three-phase systems.

[0121] Semiconductor element 6 is, for example, a thyristor, MOSFET, or IGBT. Other semiconductor elements may also be considered.

[0122] If semiconductor element 6 is constructed as an IGBT, a freewheeling diode will also be required. Other semiconductor elements may also be considered.

[0123] The drive control unit 20 is preferably a power distribution board (also called a main circuit board), i.e. a circuit board including the assembly of components, and is preferably used for drive control and power supply, preferably by means of DC voltage for drive control and power supply.

[0124] Figure 3 A device for supporting the cover is also shown. For example, the device has a plurality of lugs 13.

[0125] Cover 14 Figure 4 As shown in the diagram. The cover sometimes implements guide pins. For this purpose, the cover may have a recessed portion.

[0126] In addition, cover 14 provides protection in the event of an explosion. During performance testing, semiconductor components are used or overloaded, which can cause them to explode. The cover is used to protect the environment, especially for protecting converters or power transformers.

[0127] For this purpose, a cover, for example, is made of glass fiber reinforced polycarbonate.

[0128] Figure 4 and Figure 5 The power module 10 connected to the drive control unit 20 is shown.

[0129] Figure 7 The power module connected to the drive control unit is shown in the bird's-eye view.

[0130] Figure 5 Several electronic devices 24 are also shown.

[0131] Electronic device 24 is, for example, a capacitor, resistor, or diode. Other devices are also possible. Electronic device 24 is preferably used for drive control.

[0132] In the attached diagram, the second protruding segment 4 engages with the opening of the drive control unit. This achieves good centering.

[0133] The accompanying drawing also shows a cooling body cover or retaining frame 23.

[0134] Figure 5 Fixed element 5 is shown.

[0135] This is used to fix the drive control unit 20. The fixing element is advantageously constructed to support the drive control unit.

[0136] Furthermore, the fixing element 5 advantageously has a cavity, for example, a threaded construction in the cavity. This provides the advantage that the drive unit 5 can be fixed by means of a screw 51.

[0137] The fixing element is advantageously constructed as a device for force-fitting and / or form-fitting connection with another body.

[0138] The fixing element is, for example, a device with internal threads, which is constructed to accommodate a body with external threads, such as a screw.

[0139] Removability is ensured by using screws. Therefore, this implementation is preferred.

[0140] Alternatively, the fixing element 5 may have a cavity to secure internally threaded or self-tapping screws.

[0141] As shown in the attached figures, the fixing element may also have a first protruding segment 3. The power module 10 is preferably part of a converter system. The converter system is preferably high-performance and is particularly well-suited for drives in production machines and machine tools, as well as drives in the glass and / or packaging industries. Other applications include heating, ventilation, air conditioning, pumps and standard fans, and various converter applications.

[0142] This invention offers the following advantages: it simplifies the process, assembly, and production steps and reduces costs, particularly in terms of materials used. Significantly less material must be used for the described device compared to housings commonly used to date.

[0143] As a result, the power converter has become lighter.

[0144] Instead of screwing the packaged power unit onto the cooling body and using a base in the housing for this purpose, the described device is advantageously attached to the cooling body.

[0145] To facilitate positioning and ensure protection against torsion, at least two bolts are advantageously provided, which extend only into the minimum insertion hole, preferably a blind hole, used for positioning. The depth is preferably 1 mm to 5 mm.

[0146] The cooling element 8, together with the power unit 11, is advantageously positioned by means of at least one positioning pin that functions as a positioning tool extending into the main circuit board.

[0147] The screws 51 at the fixing components advantageously create a continuous mechanical connection from the cooling body 8 to the main circuit board. This connection also allows for direct alignment of the components via locating bolts. This promotes better structural coordination of the components.

[0148] Figure 6 The power converter 30 is shown.

[0149] The power converter 30 has at least one power module 10 as already described. The power converter may also have multiple power modules 10.

[0150] The power converter also has a drive control unit 20, which has at least one electronic device 24.

[0151] As shown in the attached figure, the power module 10 and the drive control unit 20 are interconnected.

[0152] Figure 8 Frame 2 is shown.

[0153] The frame shown has at least one first protrusion 3, wherein the first protrusion 3 is configured to engage with a groove or opening 12 of the cooling body 8.

[0154] In the accompanying drawings, the frame 2 also has exactly one second protrusion 4, wherein the second protrusion 4 is configured to engage with a groove, opening, or notch 21 of a drive unit 20 having at least one electronic device 24. The outline of the first protrusion 3, when viewed in cross-section, is at least substantially circular or annular in shape.

[0155] The outline of the second protruding segment 4, when viewed in cross-section, is at least substantially constructed in the shape of a star, wherein the star has three legs.

[0156] The attached diagram also shows longitudinal axes A3 and A4. The two segments 3 and 4 are not located on a common longitudinal axis. The two segments 3 and 4 are located on different longitudinal axes A3 and A4.

[0157] Figure 9 The outline of the second protruding segment 4 is shown in detail.

[0158] The ends of legs S1, S2 and S3 are rounded, and the rounding is constructed according to an imaginary rounding R2. R2 is a circle in the attached drawing.

[0159] The rounding R2 is a measurement used for the second protruding section 4 (also known as the Y-shaped plug or Y-shaped body). R2 can be considered to correspond to a plug with a circle having the same diameter as the second Y-shaped body.

[0160] For example, the rounded corner R1 corresponds to a drilled hole or opening in the drive control unit. This rounded corner is preferably slightly larger than the rounded corner R2.

[0161] If the variant design of the two bolts moves horizontally, the Y-shaped profile contacts the borehole later than the circular profile. The contact between the edge of the Y-shaped leg and the borehole is shown, with the circular profile visible on its left side. This has the advantage that the Y-shaped profile provides more swirl clearance before impact compared to the case with the circular profile.

Claims

1. A power module (10) having: At least one cooling element (8); At least one power unit (11), wherein, The power unit (11) includes at least one semiconductor element (6) and a substrate (7). A device (1) for surrounding a power unit (11) at least partially constructed within and / or above the cooling body (8) and for centering a drive control unit (20) relative to the power unit (11), wherein the device (1) comprises: Frame (2), wherein the frame (2) at least partially surrounds the substrate (7). At least one first protruding section (3), wherein the first protruding section (3) engages in a groove or opening (12) of the cooling body (8); At least one second protruding section (4), wherein the second protruding section (4) is configured to engage with a groove, opening, or notch (21) of a drive control unit (20) having at least one electronic device (24). The outline of the second protruding segment (4) is at least substantially constituting the shape of a star when viewed in cross-section, wherein the star has at least one first leg, a second leg and a third leg.

2. The power module (10) according to claim 1, wherein, The frame (2) completely surrounds the substrate (7).

3. The power module (10) according to claim 1 or 2, wherein, The outline of the first protruding segment (3) is at least substantially circular when viewed in cross-section, wherein the first leg and the second leg are configured such that the first leg and the second leg partially surround the outline of the first protruding segment (3) when viewed from a bird's-eye view.

4. The power module (10) according to claim 1 or 2, wherein, The length of the first leg corresponds to the length of the second leg.

5. The power module (10) according to claim 1 or 2, wherein, The first leg is longer than the third leg.

6. The power module (10) according to claim 1 or 2, wherein, The frame (2) is fixed to the cooling body (8) by means of adhesive bonding.

7. The power module (10) according to claim 1 or 2, wherein, The frame (2) is constructed in the shape of a rectangle, wherein the first protruding segment (3) is disposed at least substantially at the corner of the frame (2), and wherein the second protruding segment (4) is disposed at least substantially at the corner of the frame (2).

8. The power module (10) according to claim 7, wherein, The first protruding segment (3) is at least substantially located at the outer corner of the frame (2), wherein the second protruding segment (4) is at least substantially located at the outer corner of the frame (2).

9. The power module (10) according to claim 1 or 2, wherein, The first protruding segment (3) and the second protruding segment (4) are configured to extend in opposite directions.

10. The power module (10) according to claim 1 or 2, wherein, The first protruding section (3) and the second protruding section (4) are oriented perpendicular to the surface (82) of the cooling body (8).

11. The power module (10) according to claim 1 or 2, wherein, The frame (2) has polyphenylene sulfide.

12. The power module (10) according to claim 1 or 2, wherein, The angle between the first leg and the second leg is equal to the angle between the second leg and the third leg.

13. The power module (10) according to claim 1 or 2, wherein, The width of the legs is between 0.5mm and 2mm.

14. The power module (10) according to claim 13, wherein, The width of the legs is between 0.8mm and 1.6mm.

15. The power module (10) according to claim 14, wherein, The width of the legs is between 1.1mm and 1.3mm.

16. The power module (10) according to claim 1 or 2 further comprises a fixing element (5) for fixing the drive control unit (20).

17. A frame (2) for a power module (10) according to any one of claims 1 to 16, the frame having: At least one first protruding segment (3), wherein, The first protruding section (3) is configured to engage with a groove or opening (12) of the cooling body (8); At least one second protruding section (4), wherein the second protruding section (4) is configured to engage with a groove or opening in a drive unit (20) having at least one electronic device (24). The outline of the second protruding segment (4) is at least substantially constructed in the shape of a star when viewed in cross-section, wherein the star has at least three legs.

18. A power converter (30) having: The power module (10) according to any one of claims 1 to 16. A drive control unit (20) having at least one electronic device (24). in, The power module (10) and the drive control unit (20) are interconnected.

19. The power converter (30) according to claim 18, wherein, By engaging the second protruding segment (4) of the power module (10) into the groove or opening of the drive control unit (20), the drive control unit (20) is centered relative to the power module (10).

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