Power brick module and new energy automobile motor controller

Abstract

The invention discloses a power brick module and a new energy automobile motor controller, the power brick module comprises a module body, one side surface of the module body is provided with a water inlet, the side surface opposite to the water inlet is provided with a water outlet, the module body is internally provided with a first cooling water flow channel and a second cooling water flow channel, the first cooling water runner and the second cooling water runner are connected in parallel and then are communicated with the water inlet and the water outlet; the generator IGBT module is arranged on one surface of the module body and is adjacent to the side surfaces provided with the water inlet and the water outlet; and the driving motor IGBT module is arranged on the surface, opposite to the generator IGBT module, of the module body. According to the invention, the generator IGBT module and the driving motor IGBT module are arranged in a stacked manner in structure, so that the integration level of IGBTs in unit area can be increased; corresponding cooling water flow channels are connected in parallel, and it can be ensured that the cooling process of the generator IGBT module and the cooling process of the driving motor IGBT module are mutually independent and do not affect each other.

Description

Technical Field

[0001] This invention relates to the field of powertrain controller technology for new energy vehicles, specifically to a power brick module and a motor controller for new energy vehicles. Background Technology

[0002] Currently, the driver board and control board of the dual-motor controller are arranged in a stacked manner, with a metal shielding layer in between to prevent electromagnetic interference and high and low voltage EMC crosstalk. The driver board, based on the IGBT package (generally using HPD modules), has two IGBT modules laid horizontally and soldered onto the driver board's PCB. A water-cooling plate, thin-film capacitors, capacitive sensors, and other components are then assembled sequentially under the driver board.

[0003] However, this horizontally tiled arrangement increases the layout area. To achieve the processing target, the Y-axis dimension of the controller needs to be increased, resulting in low IGBT integration per unit area. Furthermore, the two IGBT modules in the horizontally tiled arrangement are connected in series on the cooling water channel. The cooling efficiency of the cooling water channel for the upstream and downstream IGBT modules is inconsistent. Under this configuration, the operating temperature of the downstream IGBT module is 10-15℃ higher than that of the upstream IGBT module. Summary of the Invention

[0004] This invention provides a power brick module and a new energy vehicle motor controller, which can solve the problems of low IGBT integration per unit area and low cooling efficiency of downstream IGBT modules.

[0005] In a first aspect, embodiments of the present invention provide a power brick module, comprising: The module body has a water inlet on one side and a water outlet on the side opposite to the water inlet. The module body has a first cooling water channel and a second cooling water channel. The first cooling water channel and the second cooling water channel are connected in parallel and then connected to the water inlet and the water outlet. The generator IGBT module is located on one side of the module body, adjacent to the side with the water inlet and the water outlet. A drive motor IGBT module is disposed on the surface of the module body opposite to the generator IGBT module; The first cooling water channel is used to cool the generator IGBT module; The second cooling water channel is used to cool the drive motor IGBT module.

[0006] In conjunction with the first aspect, in one implementation, it includes: A thin-film capacitor is disposed between the first cooling water channel and the second cooling water channel of the module body.

[0007] In conjunction with the first aspect, in one implementation method: The generator IGBT module has a single-layer structure, which consists of a generator HPD-IGBT module or a generator single IGBT expansion module. The drive motor IGBT module is a single-layer structure, consisting of a drive motor HPD-IGBT module or a drive motor single IGBT extension module.

[0008] In conjunction with the first aspect, in one implementation, it further includes: Multiple Pin-fin base plates, each Pin-fin base plate is also equipped with heat dissipation columns; Multiple pin-fin base plates are respectively disposed on one side of the generator IGBT module and the drive motor IGBT module, and the heat dissipation columns are respectively placed in the first cooling water channel and the second cooling water channel.

[0009] In conjunction with the first aspect, in one implementation method: The generator unit IGBT expansion module includes a first single IGBT and a first PCB driver board, wherein the first single IGBT is soldered onto the first PCB driver board. The drive motor single IGBT expansion module includes a second single IGBT and a second PCB driver board, with the second single IGBT soldered onto the second PCB driver board.

[0010] In conjunction with the first aspect, in one implementation method: The generator IGBT module has a multi-layer plate structure. The generator IGBT module is composed of multiple generator single IGBT expansion modules connected in parallel or the outermost generator HPD-IGBT module and the inner multiple generator single IGBT expansion modules connected in parallel. The first cooling water flow channel includes multiple first cooling water flow channel branches arranged in parallel, and the multiple first cooling water flow channel branches are respectively located on the side of the generator IGBT module near the drive motor IGBT module in each layer.

[0011] In conjunction with the first aspect, in one implementation method: The drive motor IGBT module has a multi-layer plate structure. The drive motor IGBT module is composed of multiple drive motor single IGBT extension modules connected in parallel or the outermost drive motor HPD-IGBT module and the inner multiple drive motor single IGBT extension modules connected in parallel. The second cooling water channel includes multiple parallel second cooling water channel branches, which are located on the side of the drive motor IGBT module closest to the generator IGBT module on each layer.

[0012] In conjunction with the first aspect, in one implementation, it further includes: Multiple Pin-fin base plates, each equipped with heat dissipation columns; A portion of the multiple Pin-fin base plates are located on the outer plate structure of the generator IGBT module and the drive motor IGBT module near the first cooling water flow channel branch or the second cooling water flow channel branch, and another portion is located on both sides of the inner plate structure of the generator IGBT module and the drive motor IGBT module. The heat dissipation columns are respectively placed in the first cooling water flow channel branch or the second cooling water flow channel branch.

[0013] In conjunction with the first aspect, in one implementation method: The generator unit IGBT expansion module and the drive motor unit IGBT expansion module use high thermal conductivity silicone grease and phase change material layers to fill the gaps in the plate-like structure.

[0014] Secondly, embodiments of the present invention provide a new energy vehicle motor controller, including the aforementioned power brick module.

[0015] This invention discloses a power brick module and a new energy vehicle motor controller. The power brick module includes: a module body with a water inlet on one side and a water outlet on the opposite side; a first cooling water channel and a second cooling water channel within the module body, the first and second cooling water channels being connected in parallel and communicating with the water inlet and the water outlet; a generator IGBT module disposed on one surface of the module body, adjacent to the side with the water inlet and the water outlet; and a drive motor IGBT module disposed on the surface of the module body opposite to the generator IGBT module; the first cooling water channel is located on the side adjacent to the generator IGBT module; and the second cooling water channel is located on the side adjacent to the drive motor IGBT module. This invention increases the integration density of IGBTs per unit area by stacking the generator IGBT module and the drive motor IGBT module structurally; and by connecting the corresponding cooling water channels in parallel, it ensures that the cooling processes of the generator IGBT module and the drive motor IGBT module are independent and do not affect each other. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a power brick module according to an embodiment of the present invention; Figure 2 This is a cross-sectional view of a first embodiment of the power brick module of the present invention; Figure 3 This is a cross-sectional view of a second embodiment of the power brick module of the present invention; Figure 4 This is a cross-sectional view of a third embodiment of the power brick module of the present invention; Figure 5 This is a schematic diagram of the generator unit IGBT expansion module of the power brick module according to an embodiment of the present invention; In the diagram: 10. Module body; 11. Water inlet; 12. Water outlet; 20. Generator IGBT module; 21. Generator HPD-IGBT module; 22. Generator single IGBT expansion module; 23. Pin-fin base plate; 231. Heat sink; 30. Drive motor IGBT module; 31. Drive motor HPD-IGBT module; 32. Drive motor single IGBT expansion module; 41. First single IGBT; 42. First PCB driver board; 43. Second single IGBT; 44. Second PCB driver board; 50. Film capacitor; 61. First cooling water channel; 62. Second cooling water channel. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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.

[0019] The front drive motor assembly of plug-in hybrid electric vehicles (PHEVs) uses a dual-motor hybrid module (DHT, Dedicated Hybrid Transmission), which consists of a P1 generator, a P3 front drive motor, a dual-motor controller assembly, a gear system, a motor housing, a cooling oil pump, and a direct-drive clutch. The dual-motor controller typically comprises a GCU (Generator Control Unit) controller and an MCUF (Motor Control Unit Front) controller. It mainly includes a control board (low-voltage control section), a drive board (high-voltage control section), power semiconductors (IGBTs), a water-cooled plate, filter components, thin-film capacitors, busbars, and current sensors. These sub-components are fixedly mounted inside the dual-motor controller housing and centrally located on top of the DHT, enabling high and low voltage electrical, mechanical, thermal management, and communication connections, thereby controlling the P1 generator (GCU), P3 front drive motor (MCUF), and clutch. The drive board and control board of the dual-motor controller are arranged in a stacked configuration, separated by a metal shielding layer to prevent electromagnetic interference and high / low voltage EMC crosstalk. The driver board, based on the IGBT packaging (generally using HPD modules), arranges two IGBT modules horizontally and solders them onto the driver board's PCB. A water-cooling plate, thin-film capacitors, capacitive sensors, and other components are then assembled sequentially beneath the driver board.

[0020] However, this horizontal layout increases the layout area, resulting in low IGBT integration per unit area. Furthermore, the two IGBT modules in the horizontal layout are connected in series on the cooling water channel, which leads to low cooling efficiency for the downstream IGBT modules.

[0021] like Figure 1 , 2 As shown, this invention discloses a power brick module, comprising: a module body 10, with a water inlet 11 on one side and a water outlet 12 on the side opposite to the water inlet 11; a first cooling water channel 61 and a second cooling water channel 62 are provided inside the module body 10, the first cooling water channel 61 and the second cooling water channel 62 are connected in parallel and communicate with the water inlet 11 and the water outlet 12; a generator IGBT module 20, which is disposed on one surface of the module body 10, adjacent to the side with the water inlet 11 and the water outlet 12; and a drive motor IGBT module 30, which is disposed on the surface of the module body 10 opposite to the generator IGBT module 20; the first cooling water channel 61 is used to cool the generator IGBT module 20; and the second cooling water channel 62 is used to cool the drive motor IGBT module 30.

[0022] The module body 10 is a hexahedron, with an inlet 11 and an outlet 12 on two opposite faces. A first cooling water channel 61 and a second cooling water channel 62 are located inside the module body 10. The first cooling water channel 61 and the second cooling water channel 62 are connected in parallel, with their inlet and outlet ends connected to the inlet 11 and outlet 12 respectively. The inlet 11 and outlet 12 are connected externally to the module body 10, forming a closed loop. The first cooling water channel 61 and the second cooling water channel 62 form a U-shape within the module body 10.

[0023] The first cooling water channel 61 and the second cooling water channel 62 are respectively arranged adjacent to the generator IGBT module 20 and the drive motor IGBT module 30. The cooling water in the first cooling water channel 61 and the second cooling water channel 62 cools the generator IGBT module 20 and the drive motor IGBT module 30 to ensure that the cooling water is at the normal operating temperature of the generator IGBT module 20 and the drive motor IGBT module 30.

[0024] In planar dual-motor hybrid modules, the generator IGBT module 20 and the drive motor IGBT module 30 have a series cooling structure, and the cooling water flow channel is designed as a single continuous flow channel. This means that the generator IGBT module 20 is cooled first, followed by the drive motor IGBT module 30. This results in a higher downstream water temperature and flow resistance for the drive motor IGBT module 30, thus affecting the system's temperature rise and efficiency. In contrast, the first cooling water flow channel 61 and the second cooling water flow channel 62 of this invention are first connected in parallel inside the module body 10, and then connected to the inlet 11 and outlet 12. This arrangement ensures that the first and second cooling water flow channels 61 and 62 can be cooled independently. After flowing through the inlet 11, the cooling water is split into the first and second cooling water flow channels 61 and 62, resulting in the initial temperature of the water flowing into the first and second cooling water flow channels 61 and 62 being the same. Therefore, the generator IGBT module 20 and the drive motor IGBT module 30 do not affect each other's cooling effect.

[0025] Since the first cooling water channel 61 and the second cooling water channel 62 are connected in parallel, the generator IGBT module 20 and the drive motor IGBT module 30 can be designed as a stacked structure. Compared with a single-layer planar structure, this increases the integration of IGBTs per unit area and can effectively save space.

[0026] This invention increases the integration density of IGBTs per unit area by connecting the generator IGBT module and the drive motor IGBT module in parallel. Furthermore, by using parallel cooling water channels to cool the generator IGBT module and the drive motor IGBT module, it is ensured that the cooling of the generator IGBT module and the drive motor IGBT module is independent and does not affect each other.

[0027] like Figure 2As shown, in one embodiment, it includes: a thin-film capacitor 50, which is disposed between the first cooling water flow channel 61 and the second cooling water flow channel 62 of the module body.

[0028] The module body 10 is designed in a "hui" (Chinese character for "return") shaped structure, with an annular cooling water circuit on the periphery and a hollow in the middle filled with the thin-film capacitor 50. The generator IGBT module 20 and the drive motor IGBT module 30 are respectively arranged in the upper and lower parts of the module body 10. The thin-film capacitor 50 is in the "hui" shaped structure formed by the first cooling water flow channel 61 and the second cooling water flow channel 62. In this way, when the first cooling water flow channel 61 and one side of the second cooling water flow channel 62 cool the generator IGBT module 20 and the drive motor IGBT module 30, the other side can cool the thin-film capacitor 50, improving the reliability of the thin-film capacitor 50. When the operating condition of the thin-film capacitor 50 is maintained at 105 °C, its lifespan can be extended to more than 15 years.

[0029] In the present invention, by disposing the thin-film capacitor between the first cooling water flow channel and the second cooling water flow channel inside the module body, the thin-film capacitor can be cooled by the first cooling water flow channel and the second cooling water flow channel to improve the reliability of the thin-film capacitor.

[0030] As Figure 2 、 5 shown, in one embodiment, the generator IGBT module 20 is a single-layer structure, which is composed of a generator HPD-IGBT module 21 or a generator single IGBT expansion module 22; the drive motor IGBT module 30 is a single-layer structure, which is composed of a drive motor HPD-IGBT module 31 or a drive motor single IGBT expansion module 32.

[0031] The generator HPD-IGBT module 21 is an IGBT module based on HPD packaging. This kind of IGBT module has limited the width and length boundaries of the controller assembly, resulting in the Y-direction boundary of the DHT assembly not being compressible, bringing great challenges to the lateral layout of the engine room.

[0032] The generator single IGBT expansion module 22, its shape can be selected according to the actual needs of users, and the arrangement and quantity of the first single IGBT 41 can also be determined according to actual requirements. And the first single IGBT 41 can be welded on both sides of the first PCB drive board 42 to further increase the integration degree of the first single IGBT 41 on the generator single IGBT expansion module 22.

[0033] The drive motor HPD-IGBT module 31 is an IGBT module based on HPD packaging. This kind of IGBT module has limited the width and length boundaries of the controller assembly, resulting in the Y-direction boundary of the DHT assembly not being compressible, bringing great challenges to the lateral layout of the engine room.

[0034] The shape of the drive motor single IGBT expansion module 32 can be selected according to the user's actual needs. The arrangement and number of the second single IGBT 43 can also be determined according to actual needs. The second single IGBT 43 can be soldered to both sides of the second PCB drive board 44 to further increase the integration of the first single IGBT 41 on the generator single IGBT expansion module 22.

[0035] like Figure 2 As shown, in one embodiment, it further includes: a plurality of Pin-fin base plates 23, wherein the Pin-fin base plates 23 are also provided with heat dissipation columns 231; the plurality of Pin-fin base plates 23 are respectively disposed on one side of the generator IGBT module 20 and the drive motor IGBT module 30, and the heat dissipation columns 231 are respectively placed in the first cooling water channel 61 and the second cooling water channel 62.

[0036] The Pin-fin base plate 23 is mounted on the generator IGBT module 20 and the drive motor IGBT module 30. The heat dissipation column 231 of the Pin-fin base plate 23 is placed in the first cooling water channel 61 and the second cooling water channel 62, and can exchange heat with the cooling water to cool down the generator IGBT module 20 and the drive motor IGBT module 30 and keep them working within the rated temperature range.

[0037] like Figure 5 As shown, in one embodiment, the generator unit IGBT expansion module 22 includes a first single IGBT 41 and a first PCB driver board 42, with the first single IGBT 41 soldered onto the first PCB driver board 42; the drive motor unit IGBT expansion module 32 includes a second single IGBT 43 and a second PCB driver board 44, with the second single IGBT 43 soldered onto the second PCB driver board 44.

[0038] The shape of the first PCB driver board 42 can be made into different shapes according to actual needs. The first single IGBT 41 is soldered to the first PCB driver board 42, and the arrangement is more flexible. In order to increase the integration of the first single IGBT 41, the first single IGBT 41 can also be soldered to both the front and back sides of the first PCB driver board 42.

[0039] The shape of the second PCB driver board 44 can be made into different shapes according to actual needs. The second single IGBT 43 is soldered to the second PCB driver board 44, and the arrangement is more flexible. In order to increase the integration of the second single IGBT 43, the second single IGBT 43 can also be soldered to both the front and back sides of the second PCB driver board 44.

[0040] The generator single-unit IGBT expansion module and drive motor single-unit IGBT expansion module designed in this invention can not only expand the area on a plane, making it more flexible and convenient to use, but also can double-sided weld the first single-tube IGBT and the second single-tube IGBT, increasing the integration of the first single-tube IGBT and the second single-tube IGBT per unit area.

[0041] like Figure 3 As shown, in one embodiment, the generator IGBT module 20 is a multi-layer plate structure. The generator IGBT module 20 is composed of multiple generator single IGBT expansion modules 22 connected in parallel, or the outermost generator HPD-IGBT module 21 and the inner multiple generator single IGBT expansion modules 22 connected in parallel. The first cooling water channel 61 includes multiple first cooling water channel branches arranged in parallel. The multiple first cooling water channel branches are respectively arranged on the side of each layer of the generator IGBT module 20 near the drive motor IGBT module 30.

[0042] The first cooling water flow channel 61 is provided with multiple first cooling water flow channel branches according to the integration requirements. The multiple first cooling water flow channel branches are connected in parallel, which can ensure that the inlet cooling water temperature of each first cooling water flow channel branch is the same, so that the cooling effect of each cooling branch is the same.

[0043] The generator IGBT module 20 has a multi-layer plate structure. Depending on the needs, the outermost layer of the generator IGBT module 20 on the side away from the module body 10 can be either a generator HPD-IGBT module 21 or a generator single IGBT expansion module 22. The multiple inner layers on the side closer to the module body 10 are generator single IGBT expansion modules 22. Since the outermost layer of the generator IGBT module 20 only has one side close to the first cooling water flow channel branch, the outermost layer of the generator IGBT module 20 is only provided with one layer of IGBTs. The multiple generator single IGBT expansion modules 22 located on the inner layers have adjacent first cooling water flow channel branches on both sides, which provides better cooling effect. Two layers of IGBTs can be soldered to increase the integration of the generator IGBT module 20.

[0044] like Figure 4 As shown, in one embodiment, the drive motor IGBT module 30 is a multi-layer plate structure. The drive motor IGBT module 30 is composed of multiple drive motor single IGBT expansion modules 32 connected in parallel, or the outermost drive motor HPD-IGBT module 31 and the inner multiple drive motor single IGBT expansion modules 32 connected in parallel. The second cooling water channel 62 includes multiple parallel second cooling water channel branches, which are respectively located on the side of each layer of the drive motor IGBT module 30 near the generator IGBT module 20.

[0045] The second cooling water channel 62 is equipped with multiple branches of the first cooling water channel according to the integration requirements. These multiple branches of the first cooling water channel are connected in parallel, which can ensure that the inlet cooling water temperature of each branch of the first cooling water channel is the same, so that the cooling effect of each cooling branch is the same.

[0046] The drive motor IGBT module 30 has a multi-layer plate structure. Depending on the needs, the outermost layer of the drive motor IGBT module 30 on the side away from the module body 10 can be either a drive motor HPD-IGBT module 31 or a drive motor single IGBT expansion module 32. The multiple inner layers on the side closer to the module body 10 are drive motor single IGBT expansion modules 32. Since the outermost layer of the drive motor IGBT module 30 only has one side close to the first cooling water flow channel branch, the outermost layer of the drive motor IGBT module 30 is only provided with one layer of IGBTs. The multiple drive motor single IGBT expansion modules 32 located on the inner layers have adjacent first cooling water flow channel branches on both sides, which provides better cooling effect. Two layers of IGBTs can be soldered to increase the integration of the drive motor IGBT module 30.

[0047] This invention designs the first and second cooling water channels as multiple parallel cooling water channel branches, with the inlets connected to the cooling water channels respectively. This ensures sufficient cooling for the multi-layered generator IGBT modules and drive motor IGBT modules, thus avoiding the problem of uneven cooling in traditional series arrangements. Simultaneously, the "U"-shaped center can cool the thin-film capacitor. This structure, through the parallel "U"-shaped cooling water channels, achieves optimized cooling efficiency.

[0048] Currently, most IGBT standard modules using HPD packaging have relatively fixed dimensions and poor scalability. This invention designs the generator IGBT module and drive motor IGBT module as a multi-layered plate structure. This not only meets the basic requirements for mounting HPD IGBT modules but also allows for parallel expansion using multiple single-tube IGBT components to meet the power requirements of the system. This expansion is not limited to the length of a single layer; for higher power requirements, it can be further expanded by stacking layers, making the power module layout more flexible, adaptable, and able to meet the customized needs of different vehicles.

[0049] like Figure 2 , 3As shown in Figure 4, in one embodiment, it further includes: a plurality of Pin-fin base plates 23, wherein heat dissipation columns 231 are provided on the Pin-fin base plates 23; a portion of the plurality of Pin-fin base plates 23 are disposed on the outer plate structure of the generator IGBT module 20 and the drive motor IGBT module 30 near the first cooling water flow channel branch or the second cooling water flow channel branch, and another portion is disposed on both sides of the inner plate structure of the generator IGBT module 20 and the drive motor IGBT module 30; the heat dissipation columns 231 are respectively placed in the first cooling water flow channel branch or the second cooling water flow channel branch.

[0050] In the traditional series planar structure, a series cooling mode is used. The generator IGBT module 20 and the drive motor IGBT module 30 are only equipped with a single-sided cooling pin-fin base plate. This cooling mode is inefficient and has the problem that the upstream cooling efficiency is higher than the downstream cooling efficiency, resulting in uneven cooling effect.

[0051] This invention, based on single-sided cooling of the Pin-fin baseplate, adds copper alloy fins (0.8mm thick) to cover the top of the chips in the inner layer IGBT expansion modules for both the generator and drive motor, achieving double-sided cooling. This cooling configuration not only satisfies single-sided water cooling for the outermost layers of the generator and drive motor IGBT modules, but also, by adding stacked water-cooling fins, enables double-sided water cooling for the inner modules of both modules, further improving cooling efficiency.

[0052] like Figure 3 , 4 As shown, in one embodiment, the generator unit IGBT expansion module 22 and the drive motor unit IGBT expansion module 32 are filled with high thermal conductivity silicone grease and phase change material layers to fill the gaps in the plate-like structure.

[0053] In the generator single IGBT expansion module 22 and the drive motor single IGBT expansion module 32, the IGBTs are filled with a high thermal conductivity silicone grease (5W / mK) + a phase change material layer (melting point 60℃) as a thermally conductive material to fill the interface gap, which can reduce the thermal resistance to 0.08K / W and reduce the junction temperature by 25℃ under the same power.

[0054] Furthermore, the module body is sealed with O-rings of fluororubber in all 10 directions. This sealing material is resistant to temperatures between -40℃ and 180℃, which meets the requirements of the operating conditions.

[0055] Furthermore, the electrical interfaces on the power brick module are protected with IP6K9K grade potting compound.

[0056] This invention improves heat transfer efficiency and further enhances cooling effect by filling the generator unit IGBT extension module and the drive motor unit IGBT extension module with high thermal conductivity silicone grease and phase change material.

[0057] The present invention also discloses a new energy vehicle motor controller, including the aforementioned power brick module.

[0058] Compared to traditional flat dual-motor controllers, which suffer from drawbacks such as low integration, uneven cooling, and poor scalability, the new energy vehicle motor controller disclosed in this invention has the following advantages: 1. Increased power density, reduced peak junction temperature of IGBTs, and elimination of imbalance issues in series cooling structures.

[0059] 2. Parallel cooling water channels ensure more uniform temperature distribution between the generator IGBT module and the drive motor IGBT module after cooling, maintaining a temperature difference within 3℃. Dual-sided cooling technology increases the thermal load capacity of the IGBTs in both modules by 40%. A multi-layer stacking design reduces volume by 42% (Y-axis width compressed to 200mm), freeing up space in the engine compartment and eliminating the need for separate housings and seals for the generator and drive motor IGBT modules. It supports free combination of single-tube IGBTs, adapting to a full range of platforms from 48V mild hybrid to 800V high voltage, and the stacked design meets the torque vector control requirements of four motors. Embedded installation improves vibration reduction performance by 50% (measured PSD vibration spectrum energy reduction), resulting in higher reliability.

[0060] 3. A single module can cover A0 to D class vehicles (power 100-400kW); dual-sided cooling compatible with SiC modules (switching frequency 50kHz+).

[0061] In the description of this invention, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0062] It should be noted that in this invention, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0063] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A power brick module, characterized by, It comprises: The module body (10) is provided with a water inlet (11) on one side, and a water outlet (12) is provided on the side opposite to the water inlet (11); the module body (10) is provided with a first cooling water channel (61) and a second cooling water channel (62); the first cooling water channel (61) and the second cooling water channel (62) are connected in parallel and then connected with the water inlet (11) and the water outlet (12); The generator IGBT module (20) is arranged on one side of the module body (10) and adjacent to the side provided with the water inlet (11) and the water outlet (12); The drive motor IGBT module (30) is arranged on the side of the module body (10) opposite to the generator IGBT module (20); The first cooling water channel (61) is used for cooling the generator IGBT module (20); The second cooling water channel (62) is used for cooling the drive motor IGBT module (30).

2. A power brick module according to claim 1, characterized in that It comprises: The thin film capacitor (50) is arranged between the first cooling water channel (61) and the second cooling water channel (62) of the module body.

3. The power brick module according to claim 1, characterized in that: The generator IGBT module (20) is a single-layer structure, which is composed of a generator HPD-IGBT module (21) or a generator single IGBT expansion module (22); The drive motor IGBT module (30) is a single-layer structure, which is composed of a drive motor HPD-IGBT module (31) or a drive motor single IGBT expansion module (32).

4. A power brick module according to claim 1, wherein, It further comprises: A plurality of Pin-fin bottom plates (23) are further provided with heat dissipation columns (231); A plurality of Pin-fin bottom plates (23) are respectively arranged on one side of the generator IGBT module (20) and the drive motor IGBT module (30), and the heat dissipation columns (231) are respectively arranged in the first cooling water channel (61) and the second cooling water channel (62).

5. The power brick module according to claim 3, characterized in that: The generator single IGBT expansion module (22) comprises a first single-tube IGBT (41) and a first PCB driving board (42), and the first single-tube IGBT (41) is welded on the first PCB driving board (42); The drive motor single IGBT expansion module (32) comprises a second single-tube IGBT (43) and a second PCB driving board (44), and the second single-tube IGBT (43) is welded on the second PCB driving board (44).

6. The power brick module according to claim 1, characterized in that: The generator IGBT module (20) is a multi-layer plate structure, which is composed of a plurality of generator single IGBT expansion modules (22) connected in parallel or a plurality of generator HPD-IGBT modules (21) and a plurality of generator single IGBT expansion modules (22) connected in parallel. The first cooling water flow channel (61) comprises a plurality of first cooling water flow channel branches arranged in parallel, and the plurality of first cooling water flow channel branches are arranged on each layer of the generator IGBT module (20) on the side close to the drive motor IGBT module (30).

7. The power brick module of claim 1, wherein: The drive motor IGBT module (30) is a multi-layer plate structure, and the drive motor IGBT module (30) is composed of a plurality of drive motor single IGBT expansion modules (32) arranged in parallel or a plurality of drive motor HPD-IGBT modules (31) and a plurality of drive motor single IGBT expansion modules (32) arranged in parallel. The second cooling water flow channel (62) comprises a plurality of second cooling water flow channel branches arranged in parallel, and the plurality of second cooling water flow channel branches are arranged on each layer of the drive motor IGBT module (30) on the side close to the generator IGBT module (20).

8. A power brick module according to claim 7, wherein, Further comprising: A plurality of Pin-fin bottom plates (23) are provided with heat dissipation columns (231); A part of the plurality of Pin-fin bottom plates (23) are arranged on the outer layer plate structure of the generator IGBT module (20) and the drive motor IGBT module (30) on the side close to the first cooling water flow channel branch or the second cooling water flow channel branch, and the other part is arranged on the inner layer plate structure of the generator IGBT module (20) and the drive motor IGBT module (30) on both sides. The heat dissipation columns (231) are respectively arranged in the first cooling water flow channel branch or the second cooling water flow channel branch.

9. The power brick module of claim 3, wherein: The generator single IGBT expansion module (22) and the drive motor single IGBT expansion module (32) are filled with a high-thermal-conductivity silicone grease and a phase change material layer in the gap of the plate structure.

10. A new energy vehicle motor controller, characterized in that, A power brick module comprising any one of claims 1-9.

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