Power stage and power module design

Abstract

A vehicle includes an inverter having a power module. The power module includes a high side bus, a low side bus, and an alternating current (AC) output bus. The high-side bus includes a first switch, wherein a high-side current is configured to flow through the first switch in a first direction. The high-side bus bar is disposed in a plane. The low-side bus includes a second switch, wherein a low-side current is configured to flow through the second switch in the first direction. The low-side bus and the high-side bus are connected in parallel. An alternating current (AC) output bus is in parallel with the high side bus and the low side bus, wherein an output current flows through the AC output bus in a second direction opposite the first direction.

Description

Technical Field

[0001] The present disclosure relates to electrical inverters for converting direct current to alternating current, and in particular, to an inverter design that reduces the occurrence of parasitic inductance in the inverter. Background Art

[0002] The inverter circuit has an inherent power loop in which a high current flows from the high voltage side to the low voltage side and back. The power loop generates a magnetic field that creates a parasitic inductance for any current path passing through the power loop. Therefore, it is desirable to design an inverter to reduce the occurrence of parasitic inductance. Summary of the invention

[0003] In an exemplary embodiment, a power module for an inverter is disclosed. The power module includes a high-side bus, a low-side bus, and an alternating current (AC) output bus. The high-side bus includes a first switch, wherein a high-side current is configured to flow through the first switch in a first direction. The low-side bus includes a second switch, wherein the low-side current is configured to flow through the second switch in the first direction. The low-side bus is connected in parallel with the high-side bus. The alternating current (AC) output bus is connected in parallel with the high-side bus and the low-side bus, wherein the output current flows through the AC output bus in a second direction opposite to the first direction.

[0004] In addition to one or more features described herein, the high-side bus and the low-side bus are coplanar with each other in a first plane, and the AC output bus is in a second plane.

[0005] In addition to one or more features described herein, the power module includes a first heat sink coupled to the first plane and a second heat sink coupled to the second plane.

[0006] In addition to one or more features described herein, the high side bus is in a first plane, the low side bus is in a second plane parallel to the first plane, and the AC output bus is in a third plane, and one of the third planes is between the first plane and the second plane, the second plane is between the first plane and the third plane, and the first plane is between the second plane and the third plane.

[0007] In addition to one or more features described herein, a first magnetic field is generated by a high-side current, a second magnetic field is generated by a low-side current, and a third magnetic field is generated by an AC output current, wherein the first magnetic field, the second magnetic field, and the third magnetic field cancel each other out to minimize or reduce the occurrence of parasitic inductance in a commutation loop.

[0008] In addition to one or more features described herein, the first switch and the second switch are coplanar with each other in a first plane, and the third switch and the fourth switch are coplanar with each other in a second plane parallel to the first plane, wherein the AC output bus is between the first plane and the second plane.

[0009] In addition to one or more features described herein, the power module further comprises a first plane, a second plane, and a third plane parallel to each other, wherein the AC output bus comprises a first AC output bus disposed between the first plane and the second plane and a second AC output bus disposed between the second plane and the third plane.

[0010] In addition to one or more features described herein, a first AC output bus is connected to switches in the first plane and in the second plane at an end of the power module, and a second AC output bus is connected to switches in the second plane and in a third plane at an end of the power module.

[0011] In addition to one or more features described herein, the second AC output bus is connected to switches in the second plane and in the third plane at the first end of the power module, and the first AC output bus is connected to switches in the first plane and in the second plane at the second end of the power module.

[0012] In addition to one or more features described herein, the inverter is one of a T-type inverter, an H-type inverter, and an X-type inverter.

[0013] In another exemplary embodiment, a vehicle is disclosed. The vehicle includes an inverter having a power module. The power module includes a high-side bus, a low-side bus, and an AC output bus, the high-side bus including a first switch, wherein the high-side current is configured to flow through the first switch in a first direction, the low-side bus including a second switch, the low-side bus is connected in parallel to the high-side bus, wherein the low-side current is configured to flow through the second switch in the first direction, and the AC output bus is connected in parallel to the high-side bus and the low-side bus, wherein the output current flows through the AC output bus in a second direction opposite to the first direction.

[0014] In addition to one or more features described herein, the high-side bus and the low-side bus are coplanar with each other in a first plane, and the AC output bus is in a second plane.

[0015] In addition to one or more features described herein, the vehicle includes a first radiator coupled to the first plane and a second radiator coupled to the second plane.

[0016] In addition to one or more features described herein, the high side bus is in a first plane, the low side bus is in a second plane parallel to the first plane, and the AC output bus is in a third plane, and one of the third planes is between the first plane and the second plane, the second plane is between the first plane and the third plane, and the first plane is between the second plane and the third plane.

[0017] In addition to one or more features described herein, a first magnetic field of the high-side current, a second magnetic field of the low-side current, and a third magnetic field generated by the AC output current cancel each other to minimize or reduce the occurrence of parasitic inductance in the commutation loop.

[0018] In addition to one or more features described herein, the first switch and the second switch are coplanar with each other in a first switch plane, and the third switch and the fourth switch are coplanar with each other in a second switch plane parallel to the first switch plane, wherein the AC output bus is between the first switch plane and the second switch plane.

[0019] In addition to one or more features described herein, the vehicle further comprises a first switch plane, a second switch plane, and a third switch plane, each switch plane being parallel to one another, wherein the AC output bus comprises a first AC output bus disposed between the first switch plane and the second switch plane and a second AC output bus disposed between the second switch plane and the third switch plane.

[0020] In addition to one or more features described herein, a first AC output bus is connected at an end of the power module to switches in a first plane of switches and a second plane of switches, and a second AC output bus is connected at an end of the power module to switches in a second plane of switches and a third plane of switches.

[0021] In addition to one or more features described herein, the second AC output bus is connected at the first end of the power module to switches in the second plane of switches and switches in the third plane of switches, and the first AC output bus is connected at the second end of the power module to switches in the first plane of switches and switches in the second plane of switches.

[0022] In addition to one or more features described herein, the inverter is one of a T-type inverter, an H-type inverter, and an X-type inverter.

[0023] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1 A vehicle according to an exemplary embodiment is shown;

[0026] Figure 2 An electrical system of a vehicle in an embodiment is shown;

[0027] Figure 3 Shows Figure 2 Schematic diagram of the branches of the inverter;

[0028] Figure 4 Shows the corresponding Figure 3 A schematic diagram of a branched power module;

[0029] FIG. 5A to FIG. 5C Possible stacking arrangements of power modules in various embodiments are shown;

[0030] Figure 6 Another stacking arrangement for a power module is shown;

[0031] Figure 7 A schematic diagram of a branch of a T-type inverter is shown;

[0032] Figure 8 A bus stack corresponding to the T-branch shown in the schematic diagram is shown;

[0033] Fig. 9 FIG. 2 shows a bus stack of a T-branch of an inverter in another embodiment;

[0034] Fig. 10A A power module having a T-type inverter in an alternative embodiment is shown;

[0035] Fig. 10B A power module having a T-type inverter in an alternative embodiment is shown;

[0036] Fig.11 A schematic diagram of an H-type branch of an inverter in an embodiment is shown;

[0037] Fig.12 The example used in the embodiment is shown Fig.11 The bus stack of H-type branch;

[0038] Fig.13 shows a perspective view of a bus stack in a first embodiment;

[0039] Fig.14 shows a perspective view of a bus stack in a second embodiment;

[0040] Fig.15 shows a perspective view of a bus stack in a third embodiment;

[0041] Fig.16 shows a perspective view of a bus stack in a fourth embodiment;

[0042] Fig.17 shows a side view of a power module with a double-sided cooling system for an H-type inverter; and

[0043] Fig.18Shown is a side view of a power module with a double-sided cooling system for an X-type inverter. DETAILED DESCRIPTION

[0044] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0045] According to an exemplary embodiment, Figure 1 A vehicle 10 is shown including a body 12 that at least partially defines an occupant compartment 14. The body 12 also supports various vehicle subsystems, including a propulsion system 16, and other subsystems such as braking subsystems, suspension systems, steering subsystems, etc., for supporting the functions of the propulsion system 16 and other vehicle components.

[0046] The vehicle 10 may be an electric vehicle (EV), a hybrid vehicle, or any other vehicle. In an embodiment, the vehicle 10 is an electric vehicle including a plurality of motors and / or a drive system. Any number of drive units may be included, such as one or more drive units for applying torque to the front wheels (not shown) and / or the rear wheels (not shown). The drive units are controllable to operate the vehicle 10 in various operating modes, such as a normal mode, a high-performance mode (in which additional torque is applied), all-wheel drive ("AWD"), front-wheel drive ("FWD"), rear-wheel drive ("RWD"), etc.

[0047] For example, the propulsion system 16 is a multi-drive system that includes a front drive unit 20 for driving the front wheels and a rear drive unit for driving the rear wheels. The front drive unit 20 includes a front motor 22 and a front inverter 24 (e.g., a front power inverter module or FPIM), as well as other components such as a cooling system. The left rear drive unit 30L includes a motor 32L and an inverter 34L. The right rear drive unit 30R includes a motor 32R and an inverter 34R. Inverters 24, 34L and 34R (e.g., power inverter units or PIMs) each convert direct current (DC) power from a high voltage (HV) battery system 40 into multi-phase (e.g., two-phase, three-phase, six-phase, etc.) alternating current (AC) power to drive the front motor 22 and the rear motors 32L and 32R.

[0048] like Figure 1 As shown, the drive system features separate motors. However, embodiments are not limited thereto. For example, instead of separate motors, multiple drives may be provided by a single machine having physically separate sets of windings.

[0049] Also like Figure 1As shown, the drive system is configured so that the front motor 22 drives the front wheels (not shown), and the rear motors 32L and 32R drive the rear wheels (not shown). However, the embodiments are not limited in this regard, as there may be any number of drive systems and / or motors at various locations (e.g., a motor driving each wheel, dual motors per axle, etc.). In addition, the embodiments are not limited to dual drive systems, as the embodiments may be used with vehicles having any number of motors and / or power inverters.

[0050] In the propulsion system 16, the front drive unit 20, the left rear drive unit 30L, and the right rear drive unit 30R are electrically connected to a battery system 40. The battery system 40 may also be electrically connected to other electrical components (also referred to as "electrical loads"), such as vehicle electronics (e.g., via an auxiliary power module or APM 42), heaters, cooling systems, etc. The battery system 40 may be configured as a rechargeable energy storage system (RESS).

[0051] In one embodiment, the battery system 40 includes a plurality of individual battery assemblies, each of which can be charged independently and can be used to independently power one or more drive systems. For example, the battery system 40 includes a first battery assembly, such as a first battery subgroup 44 and a second battery subgroup 46 connected to the front inverter 24. The first battery subgroup 44 includes a plurality of battery modules 48, and the second battery subgroup 46 includes a plurality of battery modules 50. Each battery module 48, 50 includes a plurality of individual battery cells (not shown). In various embodiments, one or more of the battery packs may include MODACS (Multi-Output Dynamically Adjustable Capacity) batteries.

[0052] Each of the front motor 22 and the rear motors 32L and 32R is a three-phase motor having a three-phase motor winding. However, the embodiments described herein are not limited thereto. For example, the motor may be any multi-phase machine powered by a multi-phase inverter, and the drive unit may be implemented using a single machine having independently grouped windings.

[0053] The battery system 40 and / or the propulsion system 16 include a switch system having various switch devices for controlling the operation of the battery packs 44 and 46 and selectively connecting the battery packs 44 and 46 to the front drive unit 20, the left rear drive unit 30L, and the right rear drive unit 30R. The switch device can also be operated to selectively connect the first battery subgroup 44 and the second battery subgroup 46 to the charging system. The charging system can be used to charge the first battery subgroup 44 and the second battery subgroup 46, and / or supply power from the first battery subgroup 44 and / or the second battery subgroup 46 to charge another energy storage system (e.g., vehicle-to-vehicle (V2V) and / or vehicle-to-everything (V2X) charging). The charging system includes one or more charging modules. For example, a first onboard charging module (OBCM) 52 is electrically connected to a charging port 54 for charging and charging from an AC system or device (such as a public AC power source). A second OBCM 53 may be included for DC charging (e.g., DC fast charging or DCFC).

[0054] In an embodiment, the switch system includes a first switch device 60 that selectively connects the first battery subgroup 44 to the inverters 24, 34L, and 34R, and a second switch device 62 that selectively connects the second battery subgroup 46 to the inverters 24, 34L, and 34R. The switch system also includes a third switch device 64 (also referred to as a "battery switch device") for selectively connecting the first battery subgroup 44 to the second battery subgroup 46 in series.

[0055] Any of a variety of controllers may be used to control the functions of the battery system 40, the switch system, and the drive unit. The controller includes any suitable processing device or unit, and an existing controller such as a drive system controller, a RESS controller, and / or a controller in a drive system may be used. For example, a controller 65 may be included to control the switch and drive control operations as discussed herein.

[0056] The controller 65 may include processing circuitry that may include an application specific integrated circuit (ASIC), electronic circuitry, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, combinatorial logic circuitry, and / or other suitable components that provide the described functionality. The controller 65 may include a non-transitory computer-readable medium storing instructions that, when processed by one or more processors of the controller 65, implement a method of heating a battery pack according to one or more embodiments detailed herein.

[0057] Figure 2An electrical system 200 of a vehicle 10 in an embodiment is shown. The electrical system 200 includes a battery 202 or a DC power source, an inverter 204 for converting DC power to AC power and from AC power to DC power, and a motor (motor) 206 operated using AC power. The motor 206 is typically a three-phase motor. The inverter 204 includes at least three branches 208a, 208b, 208c of switches. Each switch includes a switch that controls the conversion of DC power to AC power along the branch. In an embodiment, the switch includes a transistor having a diode that spans from the source of the transistor to the drain. The transistor can be controlled by a gate voltage to control the current flowing through the transistor. The transistor can be an insulated gate bipolar transistor (IGBT) or a metal oxide semiconductor field effect transistor (MOSFET) or any other suitable transistor.

[0058] Figure 3 Shows Figure 2 Schematic diagram 300 of a branch 301 (e.g., branch 208a) of an inverter 204. Branch 301 includes a high side 302 and a low side 304. High side 302 includes a high voltage bus 306 coupled to a positive DC voltage and a first switch 308 (SW1) between the high voltage bus and node A. Low side 304 includes a low voltage bus 310 coupled to a negative DC voltage and a second switch 312 (SW2) between the low voltage bus and node A. AC output bus 314 provides an output current from node A.

[0059] Figure 4 Shows the corresponding Figure 3 300 of the schematic diagram of the power module 400 of the branch 301. The power module 400 extends from a first end 402 to a second end 404. The power module 400 includes a high-side bus 406 corresponding to the high voltage bus 306, and it includes a first switch device 408 corresponding to the first switch 308 (SW1). The power module 400 includes a low-side bus 410 corresponding to the low voltage bus 310, and the low-side bus 410 includes a second switch device 412 corresponding to the second switch 312 (SW2). The first switch device 408 and the second switch device 412 are both in the form of a planar or flat tube core. The AC output bus 414 corresponds to the AC output bus 314 and is located between the first switch device 408 and the second switch device 412. The AC output bus 414 is in the form of a flat plate.

[0060] The first switching device 408, the second switching device 412, and the AC output bus 414 are aligned between the first end 402 and the second end 404. The first switching device 408 and the second switching device 412 are connected to their respective voltage sources at the first end 402. At the second end 404, the first switching device 408, the second switching device 412, and the AC output bus 414 are connected to each other at the connector 415. The high-side current 416 flows through the first switching device 408 in a first direction (e.g., from the first end 402 to the second end 404), thereby generating a high-side magnetic field BHS (first magnetic field). The low-side current 418 flows through the second switching device 412 in the first direction, thereby generating a low-side magnetic field BLS (second magnetic field). The AC output current 420 flows through the AC output bus 414 in a second direction opposite to the first direction, thereby generating an AC output magnetic field B AC (Third Magnetic Field). As a result of the arrangement of the power module 400, the high-side magnetic field B HS and low side magnetic field B LS The AC output magnetic field B at the location where the AC output bus 414 is cancelled AC This elimination minimizes or reduces the occurrence of parasitic inductance in the commutation loop including the high-side current (e.g., the current through the high-side bus 406 and the first switching device 408), the low-side current (e.g., the current through the low-side bus 210 and the second switching device 412), and the AC output current (e.g., the current through the connector 415 and the AC output bus 414), thereby reducing the wrap-around effect and electromagnetic interference.

[0061] Figures 5A-5C Possible stacking arrangements of power modules 400 in various embodiments are shown. Figure 5A A first stacking arrangement 500 is shown. The high side (HS) 302 (which includes the high voltage bus 306 and the first switch 308) is located in a first plane 502. The low side (LS) 304 (which includes the low voltage bus 310 and the second switch 312) is located in a second plane 504 that is separate from and parallel to the first plane 502. The AC output bus 314 is located in a third plane 506. The third plane 506 is parallel to the first plane 502 and the second plane 504 and is disposed between the first plane 502 and the second plane 504.

[0062] Figure 5B A second stacking arrangement 510 is shown. The first plane 502 (high side), the second plane 504 (low side) and the third plane 506 (AC output bus) are parallel to each other. The second plane 504 is disposed between the first plane 502 and the third plane 506.

[0063] Figure 5CA third stacking arrangement 520 is shown. The first plane 502 (high side), the second plane 504 (low side) and the third plane 506 (AC output bus) are parallel to each other. The first plane 502 is disposed between the second plane 504 and the third plane 506.

[0064] Figure 6 Another stacking arrangement 600 for power module 400 is shown. High side 302 (including high voltage bus 306 and first switch 308) is located in first planar die 602. Low side 304 (including low voltage bus 310 and second switch 312) is located in second planar die 604, which is coplanar in first planar die 602. AC output bus 314 is disposed in third planar die 606 located to one side (i.e., above or below) of first planar die 602 and second planar die 604. Width W of third planar die 606 AC can be chosen to be approximately equal to the width W of the first planar die 602 HS and the width W of the second planar die 604 LS The sum of .

[0065] Figure 7 A schematic diagram 700 of a T-branch of an inverter is shown. The T-branch includes a positive voltage bus 702 including a first switch SW1, a negative voltage bus 704 including a second switch SW2, and a neutral bus 706 including a third switch SW3 and a fourth switch SW4. The neutral bus 706 is connected to a neutral voltage. The positive voltage bus 702, the negative voltage bus 704, the neutral bus 706, and the AC output path 708 are connected to each other at a node A.

[0066] Figure 8 A bus stack 800 is shown corresponding to the T-branch shown in the schematic diagram 700. The bus stack 800 includes a high-side bus 802, a low-side bus 804, and a neutral bus 806. The high-side bus 802 corresponds to the positive voltage bus 702. The low-side bus 804 corresponds to the negative voltage bus 704. The neutral bus 806 corresponds to the neutral bus 706. The first AC output bus 808 and the second AC output bus 810 correspond to the AC output path 708.

[0067] The bus stack 800 extends from a first end 820 to a second end 822. At the first end 820, the high-side bus 802 is connected to the DC+ voltage, the low-side bus 804 is connected to the DC- voltage, and the neutral bus 806 is connected to the neutral voltage. At the second end 822, a connector 815 connects the low-side bus 804, the neutral bus 806, the first AC output bus 808, the second AC output bus 810, and the second end of the high-side bus 802.

[0068] The high-side bus 802, the low-side bus 804, and the neutral bus 806 each form a planar die arranged parallel to each other. The first AC output bus 808 is arranged between the high-side bus 802 and the neutral bus 806. The second AC output bus 810 is arranged between the neutral bus 806 and the low-side bus 804. The high-side current 812 (flowing through the high-side bus 802), the low-side current 814 (flowing through the low-side bus 804), and the neutral current 816 (flowing through the neutral bus 806) flow from the first end 820 to the second end 822. The AC output current flows through one or more of the first AC output bus 808 and the second AC output bus 810 in a second direction opposite to the first direction (e.g., from the second end 822 to the first end 820).

[0069] The high-side magnetic field generated by the high-side current 812 flowing through the high-side bus 802, the low-side magnetic field generated by the low-side current 814 flowing through the low-side bus 804, and the neutral bus magnetic field generated by the neutral current 816 flowing through the neutral bus 806 cancel each other at the first AC output bus 808. In addition, the high-side magnetic field generated by the high-side current 812 flowing through the high-side bus 802, the low-side magnetic field generated by the low-side current 814 flowing through the low-side bus 804, and the neutral bus magnetic field generated by the neutral current 816 flowing through the neutral bus 806 cancel each other at the second AC output bus 810.

[0070] Fig. 9 A bus stack 900 for a T-branch of an inverter in another embodiment is shown. A high-side bus 802 (and switch SW1) and a low-side bus 804 (and switch SW2) reside adjacent to each other in the same plane. A neutral bus 806 (and the third switch SW3 and the fourth switch SW4) are located on one side of the high-side bus 802 and the low-side bus 804. The AC output bus 902 is arranged between the neutral bus 806 (on one side) and the high-side bus 802 and the low-side bus 804 (on the opposite side). These buses are connected to each other at the connector 815 at the second end 822 of the bus stack 900.

[0071] Fig. 10A A power module 1000 having a T-type inverter in an alternative embodiment is shown. The power module 1000 includes a P die 1002 including a positive bus and a first switch SW1, an N die 1004 including a negative bus and a second switch SW2, and an O die 1006 including a third switch SW3 and a fourth switch SW4 and connected to a neutral point O and an AC bus 1008. The P die 1002 and the N die 1004 are arranged perpendicular to the Fig. 10AThe O-die 1006 is located in a second plane 1012 parallel to the first plane 1010. The AC bus 1008 is located in a third plane 1014, which is disposed between the first plane 1010 and the second plane 1012 and is parallel to the first plane 1010 and the second plane 1012.

[0072] Fig. 10B A power module 1015 having a T-type inverter in an alternative embodiment is shown. The power module 1015 includes a P die 1002 in a first plane 1020 perpendicular to the plane of the page and an N die 1004 in a second plane 1022 parallel to the first plane. Two O dies 1006 and 1007 are located in a third plane 1024. An AC bus 1008 is located in a fourth plane 1026. The third plane 1024 and the fourth plane 1026 are disposed between the first plane 1020 and the second plane 1022 and are parallel to the first plane and the second plane.

[0073] Fig.11 A schematic diagram 1100 of an H-type branch 1101 of an inverter in an embodiment is shown. The H-type branch 1101 includes a first branch 1102 across a power source and a second branch 1104 across a power source. The first branch 1102 includes a first high-side path 1106 and a first low-side path 1108 connected in series. The first high-side path 1106 includes a first switch SW1, and the first low-side path 1108 includes a second switch SW2. The second branch 1104 includes a second high-side path 1110 and a second low-side path 1112 connected in series. The second high-side path 1110 includes a third switch SW3, and the second low-side path 1112 includes a fourth switch SW4. A bridge path 1114 is connected to the first branch 1102 between the first switch SW1 and the second switch SW2, and is connected to the second branch 1104 between the third switch SW3 and the fourth switch SW4. The bridge path 1114 includes a fifth switch SW5 and a sixth switch SW6. The first AC output 1116 is connected to a first node A between the first switch SW1 and the second switch SW2. The second AC output 1118 is connected to a second node B between the third switch SW3 and the fourth switch SW4.

[0074] Fig.12 In the embodiment, the Fig.111. The bus stack 1200 of the H-shaped branch 1101. The switches are arranged in three layers, which are referred to herein as the top layer 1202, the middle layer 1204, and the bottom layer 1206 for ease of explanation. The first switch SW1 and the second switch SW2 are arranged adjacent to each other in the top layer 1202. The third switch SW3 and the fourth switch SW4 are arranged adjacent to each other in the bottom layer 1206. The fifth switch SW5 and the sixth switch SW6 are arranged adjacent to each other in the middle layer 1204. When viewed from the side, the switches SW2, SW5, and SW3 are in the front, and the switches SW1, SW6, and SW4 are in the back.

[0075] A first high side bus 1208 is connected to switch SW1. A first low side bus 1210 is connected to switch SW2. A second high side bus 1212 is connected to switch SW3. A second low side bus 1214 is connected to switch SW4. A first AC output bus 1216 passes between the top layer 1202 and the middle layer 1204 and is connected to switches SW1, SW2, and SW5 at a first connector 1226. A second AC output bus 1218 passes between the middle layer 1204 and the bottom layer 1206 and is connected to switches SW3, SW4, and SW6 at a second connector 1228. A bridge bar 1230 connects switches SW5 and SW6.

[0076] Fig.13 A perspective view 1300 of a bus stack 1200 in a first embodiment is shown. The perspective view shows the connections between switches. The first AC output bus 1216 extends from the first connector 1226 and passes between the top layer 1202 and the middle layer 1204. Therefore, the magnetic fields caused by the current flowing in the top layer 1202, the middle layer 1204 (switches SW1, SW2, and SW5) and the first AC output bus 1216 cancel each other at the first AC output bus 1216. The second AC output bus 1218 extends from the second connector 1228 and passes between the middle layer 1204 and the bottom layer 1206. Therefore, the magnetic fields caused by the current flowing in the middle layer 1204, the bottom layer 1206 (switches SW3, SW4, and SW6) and the second AC output bus 1218 cancel each other at the second AC output bus 1218.

[0077] Fig.14 A perspective view 1400 of a bus stack 1200 in a second embodiment is shown. For ease of explanation, switches are arranged in two layers, referred to herein as a top layer 1402 and a bottom layer 1404. A first switch SW1, a second switch SW2, a third switch SW3, and a fourth switch SW4 are arranged adjacent to each other in the top layer 1202. A switch SW5 is arranged in the bottom layer 1404 below the first switch SW1 and the second switch SW2. A switch SW6 is arranged in the bottom layer 1404 near the fifth switch SW5 and below the third switch SW3 and the fourth switch SW4.

[0078] A first connector 1406 (corresponding to node A) connects switches SW1, SW2, and SW5 at a second end. A first AC output bus 1408 extends from the first connector 1406 and passes between the top layer 1402 and the bottom layer 1404. Magnetic fields caused by currents flowing in the top layer 1402, the bottom layer 1404 (switches SW1, SW2, and SW5), and the first AC output bus 1408 cancel each other at the first AC output bus 1408 to minimize or reduce the total parasitic inductance.

[0079] The second connector 1410 (corresponding to the node B) connects the switches SW3, SW4, and SW6 at the second end. The second AC output bus 1412 extends from the second connector 1410 and passes between the top layer 1402 and the bottom layer 1404. The magnetic fields caused by the currents flowing in the top layer 1402, the bottom layer 1404 (switches SW3, SW4, and SW6), and the second AC output bus 1412 cancel each other at the second AC output bus 1412 to minimize or reduce the total parasitic inductance.

[0080] Fig.15 A perspective view 1500 of a bus stack 1200 in a third embodiment is shown. The switches are arranged in three layers: a top layer 1502 (including switches SW1 and SW2), a middle layer 1504 (including bidirectional switches SW5), and a bottom layer 1506 (including switches SW3 and SW4). The layers extend from a first end 1508 to a second end 1510. A first connector 1512 (corresponding to node A) connects switches SW1, SW2, and SW5 at the second end 1510. A first AC output bus 1514 extends from the first connector 1512 and passes between the top layer 1502 and the middle layer 1504 toward the first end 1508. The magnetic fields caused by the currents flowing in the top layer 1202, the middle layer 1204 (switches SW1, SW2, and SW5), and the first AC output bus 1514 cancel each other at the first AC output bus 1514 to minimize or reduce the total parasitic inductance.

[0081] The second connector 1516 connects the switches SW3, SW4, and SW5 at the first end 1508. The second AC output bus 1518 extends from the second connector 1516 and passes between the middle layer 1204 and the bottom layer 1206 toward the second end 1510. The magnetic fields caused by the currents flowing in the middle layer 1504, the bottom layer 1506 (switches SW3, SW4, and SW5), and the second AC output bus 1518 cancel each other at the second AC output bus 1518 to minimize or reduce the total parasitic inductance.

[0082] Fig.16A perspective view 1600 of the bus stack 1200 in the fourth embodiment is shown. The first connector 1512 connects the switches SW1, SW2, and SW5 at a second end, and the first AC output bus 1514 extends from the first connector 1512 in a direction away from the switches. Similarly, the second connector 1516 connects the switches SW3, SW4, and SW6 at a second end, and the second AC output bus 1518 extends from the second connector 1516 in a direction away from the switches.

[0083] Fig.17 A side view 1700 of a power module having a double-sided cooling system for an H-type inverter 1710 is shown, including switches SW1-SW6. The side view 1700 shows a switch portion 1702, which includes switches SW1, SW2, and SW5 on a first side and switches SW3, SW4, and SW6 on a second side opposite to switches SW1, SW2, and SW5, respectively. A first heat sink 1704 is coupled to the first side, and a second heat sink 1706 is coupled to the second side.

[0084] Fig.18 A side view 1800 of a power module with a double-sided cooling system for an X-type inverter 1810 is shown, including switches SW1-SW8 and diodes D1 and D2. The side view 1800 shows a switch portion 1802, which includes switches SW5, SW6, SW7, and SW8 on a first side and switches SW1, SW2, SW3, and SW4 on a second side. Switches SW1 and SW8 are opposite to each other. Switches SW2 and SW7 are opposite to each other. Switches SW3 and SW6 are opposite to each other. Switches SW4 and SW5 are opposite to each other. Diode D1 is located on the first side and D2 is located on the second side. A first heat sink 1804 is coupled to the first side, and a second heat sink 1806 is coupled to the second side.

[0085] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0086] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0087] Unless otherwise indicated herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0088] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0089] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A power module for an inverter, comprising: a high-side bus comprising a first switch, wherein a high-side current is configured to flow through the first switch in a first direction; a low-side bus comprising a second switch, the low-side bus being connected in parallel with the high-side bus, wherein a low-side current is configured to flow through the second switch in the first direction; as well as An alternating current (AC) output bus is connected in parallel to the high-side bus and the low-side bus, wherein an output current flows through the AC output bus in a second direction opposite to the first direction.

2. The power module according to claim 1, wherein: The high-side bus and the low-side bus are coplanar with each other in a first plane, and the AC output bus is in a second plane.

3. The power module according to claim 1, wherein: The high-side bus is in a first plane, the low-side bus is in a second plane parallel to the first plane, and the AC output bus is in a third plane, and one of the following: (i) the third plane is between the first plane and the second plane; (ii) the second plane is between the first plane and the third plane; and (iii) the first plane is between the second plane and the third plane.

4. The power module according to claim 1, wherein a first magnetic field generated by the high-side current, a second magnetic field generated by the low-side current, and a third magnetic field generated by the AC output current cancel each other to minimize or reduce the occurrence of parasitic inductance in a commutation loop.

5. The power module of claim 1 , wherein the first switch and the second switch are coplanar with each other in a first plane, and the third switch and the fourth switch are coplanar with each other in a second plane parallel to the first plane, wherein the AC output bus is between the first plane and the second plane.

6. A vehicle comprising: An inverter, wherein the inverter has a power module, and the power module includes: a high-side bus comprising a first switch, wherein a high-side current is configured to flow through the first switch in a first direction; a low-side bus comprising a second switch, the low-side bus being connected in parallel to the high-side bus, wherein a low-side current is configured to flow through the second switch in the first direction; and An AC output bus is connected in parallel with the high-side bus and the low-side bus, wherein an output current flows through the AC output bus in a second direction opposite to the first direction.

7. The vehicle according to claim 6, wherein: The high-side bus is in a first plane, the low-side bus is in a second plane parallel to the first plane, and the AC output bus is in a third plane, and one of: (i) the third plane is between the first plane and the second plane; (ii) the second plane is between the first plane and the third plane; and (iii) the first plane is between the second plane and the third plane.

8. The vehicle according to claim 6, wherein: The first magnetic field of the high-side current, the second magnetic field of the low-side current, and the third magnetic field generated by the AC output current cancel each other to minimize or reduce the occurrence of parasitic inductance in the commutation loop.

9. The vehicle of claim 6, wherein the first switch and the second switch are coplanar with each other in a first switch plane, and the third switch and the fourth switch are coplanar with each other in a second switch plane parallel to the first switch plane, wherein the AC output bus is between the first switch plane and the second switch plane.

10. The vehicle of claim 6, further comprising a first switch plane, a second switch plane, and a third switch plane, each switch plane being parallel to each other, wherein the AC output bus comprises a first AC output bus disposed between the first switch plane and the second switch plane and a second AC output bus disposed between the second switch plane and the third switch plane.

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