System and method for assembling power module device with molded bracket

Abstract

The invention provides a bracket for positioning, centering and insulating components of a power module device. The bracket comprises: a plurality of power supply terminal slots for positioning and centering power supply terminals; the two bus ducts are used for positioning and centering the two buses; a plurality of power module slots for positioning and centering the power modules; a plurality of locking grooves; and a plurality of insulators disposed in the plurality of power supply terminal slots and the plurality of power supply module slots. The plurality of locking clamps are integrated on the side surfaces of the plurality of power supply terminal slots, the peripheral areas at the two ends of the bracket and the surface of the bracket; and a removable locking element located at the edge of the bracket prior to removal.

Description

Technical Field

[0001] This disclosure relates to a bracket for a power module device, including an inverter, a converter, an electric drive, etc. Background Technology

[0002] Existing power module devices rely on individual components to achieve different functions, including assembly, positioning, and insulation. Specifically, existing inverter power stages require step-by-step positioning and assembly of components such as power modules, power boards, and screws. After assembly, the components are secured with screws to ensure correct positioning and withstand mechanical vibration and shock. Furthermore, plastic insulators provide electrical isolation between each screw and the heatsink / base plate. However, relying on individual components for multiple functions can complicate the manufacturing process, leading to more assembly errors and longer cycle times. Particularly during inverter power stage assembly, problems such as component positioning errors, other assembly mistakes, and component damage are prone to occur.

[0003] US Patent 10,772,242B2 discloses a power module integrated into an inverter. The power module includes a positioner with multiple slots in which multiple transistors are positioned and connected to the slots via at least one snap-fit. The power module may also include a laminated bus connected to a gate drive printed circuit board and positioned on a first surface of the positioner. In some embodiments, the power module may be connected to a subassembly including a positive bus, a negative bus, and a mounting bracket for aligning the positive and negative buses.

[0004] The aforementioned disclosure relies on positioners to locate certain components of the power module, and on brackets to locate certain components of the sub-assemblies and connect the power module to the sub-assemblies. While positioners and brackets can position certain inverter components as required to reduce potential assembly errors, they cannot reduce assembly errors associated with insulation components and other inverter components (including power terminals, power boards, etc.). Summary of the Invention

[0005] The inventors have recognized the aforementioned problems and provide solutions that at least partially address them, including a bracket for a power module device, configured with: multiple terminal slots for positioning and centering power terminals; two busbar slots for positioning and centering two busbars; multiple module slots for positioning and centering power modules; connections for connecting multiple terminals, two busbars, and multiple power boards to the bracket; multiple insulators disposed in the power terminal slots and power module slots, each insulator positioning a fastener that connects the multiple power terminals and two busbars to the heat sink of the power module device; multiple locking clips integrated into the sides of the multiple power terminal slots, the periphery of both ends of the bracket, and the bracket surface; and removable locking elements located at the edges of the bracket (before disassembly). In this way, the bracket can perform multiple functions, including positioning, centering, and insulating various components of the power module device. Because the bracket has multiple functions, the number of components in the power module device can be reduced, thereby reducing assembly steps, reducing assembly errors, and improving the quality of the power module device.

[0006] It should be noted that the above overview is intended to briefly introduce some concepts further elaborated in the detailed description, and is not intended to define the key or essential features of the claimed subject matter—its scope of protection is clearly defined only by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to specific embodiments that address the deficiencies described above or in any part of this disclosure.

[0007] The foregoing description and other advantages of the bracket and inverter assembly and assembly method proposed in this invention will become apparent to those skilled in the art after the following detailed description of exemplary embodiments of the components and methods in conjunction with the accompanying drawings. The drawings described herein illustrate specific embodiments of the subject matter of this disclosure and are intended to illustrate the principles and technical solutions selected by this disclosure. However, it should be noted that these drawings do not cover all possible implementations of the subject matter of this disclosure, nor do they limit the scope of protection of this disclosure in any way. Attached Figure Description

[0008] Figure 1 A vehicle according to one or more embodiments of the present disclosure is illustrated schematically.

[0009] Figure 2 An exploded view of an inverter assembly with integrated support brackets is shown schematically.

[0010] Figure 3 The schematic diagram shows the integration with Figure 1 A top view of the bracket inside the inverter assembly.

[0011] Figure 4 schematically shown Figure 1 The diagram shows a cross-sectional view of the inverter assembly.

[0012] Figure 5 An example method for assembling inverter components is illustrated schematically.

[0013] Figures 6A-6E schematically shown Figure 1 The different steps involved in assembling the inverter components are shown.

[0014] Figure 7 A schematic first perspective view of the assembled inverter assembly is shown.

[0015] Similar components may be represented using the same reference numerals in different figures. According to some embodiments, Figure 2-4 and Figure 6A-7 The components shown are presented in scale. Detailed Implementation

[0016] This document describes a power module assembly (such as an inverter assembly) integrating a molded bracket with removable locking elements. This bracket is used to position, center, and insulate various components of the power module assembly, and provides a method for assembling the power module assembly. The bracket is configured to position multiple power terminals, two busbars (e.g., positive and negative busbars), and multiple power modules of the power module assembly. The bracket also includes multiple insulators for electrically isolating multiple fasteners from other components of the power module assembly. The bracket also integrates multiple locking slots and locking clips for connecting the multiple power terminals, the two busbars, and the multiple power modules to the bracket.

[0017] Figure 1 The illustration schematically shows a vehicle integrating an inverter based on a bracketed inverter assembly. Figure 2 An exploded view of the inverter is depicted schematically. Figure 3 Depicting integration into Figure 2 Example bracket within the inverter assembly. Figure 4 A schematic cross-sectional view of the inverter assembly is shown. Figure 5 An example method for assembling inverter components is illustrated. Figure 6A , 6B 6C, 6D, and 6E schematically show the assembly. Figure 2 The different steps of the inverter assembly are shown. Figure 7 The diagram schematically shows a first perspective view of the assembled inverter assembly.

[0018] Figure 1Vehicle 100 is shown. Vehicle 100 can be a light, medium, or heavy-duty vehicle. Vehicle 100 includes an electric drive unit 102. Therefore, vehicle 100 can be an electric vehicle (e.g., a pure electric vehicle or a hybrid electric vehicle containing an internal combustion engine) or a conventional internal combustion engine (ICE) vehicle. Specifically, electric drive unit 102 can power one or more drive axles 140. For example, in one application scenario, electric drive unit 102 can include two electric drive axles equipped with independent traction motors. In another embodiment, electric drive unit 102 can include a single traction motor that distributes power to one or both drive axles depending on vehicle operating conditions and / or driver preferences. In both embodiments, electric drive unit 102 can function as a four-wheel electric drive unit (e.g., an all-wheel electric drive unit), where both front and rear drive wheels are powered under certain operating conditions. In a hybrid vehicle embodiment, vehicle 100 may include one axle powered by an electric motor and another axle powered by an internal combustion engine while in operation. In other embodiments, the electric drive unit may be integrated into a front-wheel drive powertrain or a rear-wheel drive powertrain.

[0019] The electric drive unit 102 includes a prime mover 104 (e.g., an electric motor, internal combustion engine, etc.) mechanically connected to a transmission 106. In this electric vehicle example, the electric motor may be a permanent magnet (PM) type, typically an alternating current (AC) motor. In this example, the prime mover 104 receives power from an inverter 110, which in turn draws electrical energy from one or more energy storage devices 112 (e.g., a traction battery, capacitor, or a combination thereof). The inverter 110 may be connected to... Figure 2 and Figure 3 The inverter assembly and bracket integration are shown. Arrow 150 indicates the mechanical power transmission between the prime mover 104 and the transmission 106. Arrow 152 indicates the electrical transmission between the prime mover 104 and the inverter 110, and arrow 154 indicates the electrical transmission between the inverter 110 and the energy storage device 112. Mechanical power can be transmitted from the transmission 106 to one or more drive shafts 140 via the differential 114.

[0020] The vehicle 100 also includes a control system 170, which is equipped with a controller 172 (e.g., an electronic control unit (ECU), such as a transmission control unit (TCU), a vehicle control unit (VCU), or a combination thereof). The controller 172 may be designed to execute control strategies. To implement the aforementioned vehicle control functions, the vehicle controller may include a memory 174 storing instructions executable by a processor 176 to implement the vehicle control strategies.

[0021] One or more input devices 178 (such as a drive mode selector, accelerator pedal, brake pedal, touch interface, or combinations thereof) can be connected to the controller 172 via electronic communication as indicated by arrow 180. The drive mode selector can be a button, switch, touch interface, slider, or a combination thereof, enabling the driver to trigger the disengagement of the transmission 106 from the drive wheels. For example, when the vehicle is equipped with a second electric axle, the mode selector can switch the vehicle from two-wheel drive mode to four-wheel drive mode. The controller 172 can control one or more components of the vehicle 100 via one or more actuators 179. For example, actuator 179 can control the disengagement of the transmission 106 from the drive wheels.

[0022] Figure 1 The coordinate axis system 199 is provided for reference. In one example, the z-axis may be a vertical axis (e.g., parallel to the gravity axis), the x-axis may be a transverse axis (e.g., a horizontal axis), and the y-axis may be a longitudinal axis. However, in other examples, the axes may have different orientations.

[0023] Figure 2 The inverter assembly 200 shown is equipped with a bracket 212 for positioning, centering, and insulating the components of the assembly. The inverter assembly 200 also includes: a base plate 202, multiple power modules, a removable locking element 206 for the bracket 212, multiple power terminals 208, a pair of busbars 210, multiple support members 214, a power board 216, multiple spacers 218, and multiple fasteners 220. The base plate 202 serves as a heat sink, conducting heat generated by the electrical components (e.g., busbars, power terminals, power board, etc.) to the outside of the inverter assembly 200, thereby reducing the risk of component damage.

[0024] The bracket 212 ensures the correct positioning of the components of the inverter assembly 200. Specifically, the bracket 212 positions multiple power modules (including a first power module 204a, a second power module 204b, and a third power module 204c), a pair of buses 210, and multiple power terminals 208. This ensures good contact between the power modules, the pair of buses 210, the multiple power terminals 208, and the base plate 202. The bracket 212 also supports the construction of sub-modules, which facilitate subsequent assembly steps of the inverter assembly. Furthermore, the structural design of the bracket 212 prevents the power board 216 from bending when connected to the pair of buses 210, the multiple power terminals, and the multiple power modules. Simultaneously, the bracket 212 effectively compensates for tolerance deviations in flatness and smoothness of the power board 216.

[0025] In particular, by integrating snap-fit ​​and blocking fasteners into the bracket, the power board 216, a pair of buses 210, and multiple power modules can be positioned and centered without the need for screws or other fasteners. Therefore, ease of operation can be improved when relying on pre-assembled modules rather than individual components to handle the power stage sub-components of the inverter assembly 200. This improved ease of operation can shorten cycle time, as the assembly of the power stage sub-components can be performed in parallel with the inverter assembly line. Furthermore, the bracket 212 employs a mistake-proof design to ensure that the components of the inverter assembly 200 are not misassembled due to improper assembly.

[0026] Furthermore, the bracket 212 can be made of a plastic material with a predetermined Comparison Tracking Index (CTI), providing sufficient electrical insulation for high-voltage or high-current components in the inverter assembly 200. Specifically, the bracket 212 is configured to provide electrical insulation to the power board 216, a pair of buses 210, and multiple power modules. Additionally, the bracket 212 also serves to achieve electrical insulation between the high-voltage, high-current components within the inverter assembly 200 and the base plate 202. This insulation effect is achieved through insulating fasteners (e.g., insulating screws) that connect the high-voltage, high-current components to the base plate 202. Furthermore, due to the use of a plastic material with sufficient CTI between the high-voltage / high-current components and the base plate 202, insulation distances such as creepage distances and gaps are shortened. This reduction in insulation distance allows for a reduction in the size of the inverter assembly 200. The removable locking element of the bracket 212 is made of the same plastic material as the rest of the bracket and is manufactured using the same mold.

[0027] A pair of buses 210 can transmit power from a power source (such as a vehicle battery) to other components of the inverter assembly 200, such as power board 216. Power board 216 may include multiple DC bus capacitors, and the pair of buses 210 can be used as DC buses. Power board 216 can transmit electrical signals to multiple power modules (such as first power module 204a, second power module 204b, and third power module) via multiple power terminals 208. Thus, power board 216 can transmit electrical signals to first power module 204a via the first power terminal. Furthermore, power board 216 can transmit electrical signals to second power module 204b via the second power terminal. Power board 216 can transmit electrical signals to third power module 204c via the third power terminal. The multiple power modules can convert direct current (DC) to alternating current (AC), which can be transmitted to devices such as vehicle motor windings.

[0028] Multiple support members 214 can be coupled to multiple power terminals 208 and a pair of busbars 210 to assist in positioning the multiple power terminals and the pair of busbars. Specifically, a single support member can position any component of the power terminals or busbars. Multiple support members 214, multiple spacers 218, and multiple fasteners penetrate the bracket 212 and the power board 216, connecting the multiple power terminals 208, multiple power modules, and the pair of busbars to the base plate 202.

[0029] Figure 3 A bracket 300 is shown for positioning, centering, and insulating the various components of the power module equipment. This bracket 300 can be considered as... Figure 2 A specific embodiment of the central support 212. The support 300 includes a first part 312, a second part 314, a third part 316, and a fourth part 318, used for positioning and centering multiple power terminals, two busbars, multiple power modules, and insulators for positioning multiple fasteners. Specifically, by cooperating with multiple power board slots on the power board and multiple locking slots 320 fixed at different positions on the support 300, the positioning and centering of multiple power terminals, two busbars, multiple power modules, and multiple insulators can be achieved.

[0030] Each insulator can position a fastener that connects multiple power terminals and two busbars to the heat sink or base plate of the power module device. Multiple locking slots extend through the bracket 300, each located beside one of multiple locking clips—these locking clips extend from the top or bottom surface of the bracket 300. Each locking clip can connect and secure multiple power terminals, two busbars, and multiple power modules to the bracket 300.

[0031] The length and width of the first part 312 are both greater than those of the second part 314, the third part 316, and the fourth part 318. The length of the second part 314 is greater than that of the third part 316, but the width is smaller than that of the third part 316. The length of the fourth part 318 is greater than that of the second part 314 and the third part 316, but the width is smaller than that of the second part 314 and the third part 316. The first part 312 is a truncated rounded rectangle, with the truncation occurring at each corner of the part.

[0032] The second part 314 is connected to the first part 312 on one side, and its other side is a truncated rounded rectangle. The truncated surface of the second part 314 is located on one side, and this truncated surface is opposite to the connecting surface of the first part 312. The third part 316 is rectangular and connected to the second part 314. The fourth part 318 is stadium-shaped and connected to the third part.

[0033] Multiple power terminal slots are used to position and center multiple power terminals of the power module device. These terminal slots are generally rectangular, and brackets 300 extend inward at both ends of each slot to position pairs of insulators within the slot. The multiple sets of power terminal slots may include a first power terminal slot 310a, a second power terminal slot 310b, and a third power terminal slot 310c. Specifically, two power terminal slots are provided within a first portion 312: one located at one end of the first portion 312, and the other at the other end of the portion. Multiple insulators may be positioned within the multiple power terminal slots, including a first insulator 306a, a second insulator 306b, a sixth insulator 306f, a seventh insulator 306g, a fourteenth insulator 306n, and a fifteenth insulator 306o.

[0034] For example, a first power terminal slot 310a and a second power terminal slot 310b may be located within a first portion 312. The first power terminal slot 310a is located at one end of the first portion 312, and the second power terminal slot 310b is located at the other end of the same portion. Furthermore, another power terminal slot extends from a fourth portion 318 into a portion of a third portion 316. For example, a third power terminal slot 310c may extend from the fourth portion 318 into a portion of the third portion. Therefore, the third power terminal slot 310c is located within both the third portion 316 and the fourth portion 318.

[0035] The fastener extends inward into the slots at both ends of the first power terminal slot 310a, the second power terminal slot 310b, and the third power terminal slot 310c. In this way, a pair of insulators can be provided in each of the three slots. Specifically, the first insulator 306a and the second insulator 306b can be positioned in the third power terminal slot 310c, the sixth insulator 306f and the seventh insulator 306g can be positioned in the first power terminal slot 310a, and the fourteenth insulator 306n and the fifteenth insulator 306o can be positioned in the second power terminal slot 310b. In this way, each insulator can position a fastener that connects multiple power terminals to the heat sink (e.g., base plate) of the power module device.

[0036] In addition, multiple locking clips are integrated into the sidewall of the power terminal slot, the outer edge of one end of the bracket 300, and the surface of the bracket 300. This locking clip assembly includes a first locking clip 302a, a second locking clip 302b, a third locking clip 302c, a fourth locking clip 302d, a fifth locking clip 302e, a sixth locking clip 302f, and a seventh locking clip 302g. The first locking clip 302a can be integrated into the side of the first power terminal slot 310a near the edge of the first portion 312 of the bracket 300. The second locking clip 302b can be integrated into the side of the second power terminal slot 310b near the edge of the first portion 312 of the bracket 300. The first locking clip 302a is located at the distal end of the first portion 312 of the bracket 300 and is positioned opposite to the second locking clip 302b. The third locking clip 302c can be integrated into the side of the third power terminal slot 310c, which belongs to the fourth portion 318 of the bracket 300.

[0037] The fourth locking clip 302d and the fifth locking clip 302e extend from the surface of the bracket 300 and are located on the periphery of one end of the bracket at the fourth portion 318. A gap exists between the fourth locking clip 302d and the fifth locking clip 302e. In contrast, the sixth locking clip 302f and the seventh locking clip 302g extend from the surface of the bracket 300 and are located on the periphery of the area of ​​the first portion 312 at the other end of the bracket. A gap exists between the sixth locking clip 302f and the seventh locking clip 302g. The fourth locking clip 302d and the sixth locking clip 302f are approximately aligned, and the fifth locking clip 302e and the seventh locking clip 302g are approximately aligned.

[0038] Multiple power module slots are used to position and centrally mount multiple power modules in the power module assembly. These power module slots are rounded rectangles, with length and width dimensions larger than the multiple power terminal slots. The multiple power module slots may include a first power module slot 304a, a second power module slot 304b, and a third power module slot 304c. Two of these power module slots are located in the central area of ​​the first portion 312 and are spaced apart from each other. One power module slot is offset from a power terminal slot located at one end of the first portion 312, and the other power module slot is offset from another power terminal slot located at the other end of the first portion.

[0039] For example, the first power module slot 304a and the second power module slot 304b are located in the middle region of the first portion 312 and are spaced apart from each other. The first power module slot 304a is staggered and aligned with the first power terminal slot 310a, which is located at one end of the first portion; the second power module slot 304b is staggered and aligned with the second power terminal slot 310b, which is located at the other end of the first portion 312. Thus, the first power module slot 304a is spaced apart from the first power terminal slot on one side of the first portion 312 and from the second power module slot 304b on the other side of the first portion. Furthermore, the second power module slot 304b is spaced apart from the second power terminal slot 310b on the other side of the second power module slot.

[0040] Furthermore, another power module slot extends from a portion of the third portion 316 into the second portion 314 and aligns with a power terminal slot located in the fourth portion 318. More specifically, a third power module slot 304c extends from a portion of the third portion 316 into the second portion 314 and aligns with a third power terminal slot 310c. Thus, the third power module slot 304c is located within the second portion 314 and the third portion 316 of the bracket.

[0041] The bracket extends to one side of each power module slot (e.g., the first power module slot 304a, the second power module slot 304b, and the third power module slot 304c) to position three insulators within the corresponding power module slot. The side of the bracket that extends into the corresponding power module slot is closest to the center of the bracket. In this way, three insulators can be arranged in the first power module slot 304a, the second power module slot 304b, and the third power module slot 304c, respectively.

[0042] For example, the third insulator 306c, the fourth insulator 306d, and the fifth insulator 306e can be arranged on the side of the third power module slot 304c near the center of the bracket 300. Similarly, the eighth insulator 306h, the ninth insulator 306i, and the tenth insulator 306j can be arranged on the side of the first power module slot 304a near the second power module slot 304b. The eleventh insulator 306k, the twelfth insulator 306l, and the thirteenth insulator 306m can be arranged on the side of the second power module slot 304b near the first power module slot 304a.

[0043] Two busbar slots are used to position and centrally fix the positive and negative busbars. These two busbar slots are typically circular and located near both ends of the second part 314 of the bracket, with a power terminal slot between them. For example, the two busbar slots may include a positive busbar slot 308a and a negative busbar slot 308b. The positive busbar slot 308a may be located on one side of the third power module slot 304c, while the negative busbar slot may be located on the other side of the third power module slot in the second part 314 of the bracket 300.

[0044] The bracket 300 includes a removable locking element 301 located at the edge of the bracket (before disassembly) for locking components of the power module assembly. For example, the removable locking element 301 can interconnect multiple power terminals, two busbars, and multiple power modules. The removable locking element 301 can be connected to a sixth locking clip 302f and a seventh locking clip 302g. The locking element can be manually removed by applying pressure to separate it from the bracket 300.

[0045] The removable locking element 301 includes a rectangular segment 301a, a first end 301b, and a second end 301c. The first end 301b is located at one end of the removable locking element 301, and the second end 301c is located at the other end. The first end 301b and the second end 301c each extend outward from one end of the rectangular segment 301a and from their respective sides.

[0046] The first end 301b and the second end 301c include a first region 303a, a second region 303b, a third region 303c, and a fourth region 303d. The first region 303a is approximately rectangular and located near the end of the rectangular segment. The first end 301b and the second end 301c include a stepped structure extending from the first region, which is formed by the second region 303b and the third region 303c. Both the second region 303b and the third region 303c are quarter-circle arcs. The second region 303b is located above the third region 303c. The fourth region 303d includes a first surface extending vertically from the first region 303a and a second surface at an angle to the first surface. During the assembly of the power module device, the fourth region 303d connects the detachable locking element 301 to the bracket 300.

[0047] The bracket 300 may also include a plurality of protruding members extending through a single surface of the bracket to another surface. These protrusions may include a first protrusion 322a, a second protrusion 322b, a third protrusion 322c, and a fourth protrusion 322d. The first protrusion 322a may be located at one end of the fourth portion 318, and the second protrusion 322b may be located at the other end of the same portion. The third protrusion 322c and the fourth protrusion 322d may be positioned in the peripheral area of ​​the first portion 312 of the bracket. The third protrusion 322c may be arranged adjacent to the sixth latch 302f, and the fourth protrusion 322d may be arranged adjacent to the seventh latch 302g.

[0048] Figure 4 A cross-sectional view 400 of an inverter assembly is shown. This inverter assembly can be used for... Figure 2 This diagram illustrates one embodiment of the inverter assembly 200. A cross-sectional view 400 depicts the assembled inverter assembly, wherein a bracket 406 is used to position, center, and insulate multiple power terminals, multiple power modules, a positive bus, and a negative bus. In the assembled state, multiple sets of power terminals, positive buses, and negative buses are secured within the bracket by multiple support members 410.

[0049] Furthermore, in the assembled state, multiple fasteners pass through the insulators of the bracket and the through holes of the power board 404, connecting and fixing the power board 404, multiple power terminals, multiple power modules, positive busbar, and negative busbar to the base plate 402. The multiple insulators may include a first insulator 412a, a second insulator 412b, and a third insulator 412c, and the multiple fasteners may include a first fastener 414a, a second fastener 414b, and a third fastener 414c. Multiple spacers 408 are disposed inside the power board 404.

[0050] For example, the first fastener 414a may be located within the first insulator 412a, the second fastener 414b may be located within the second insulator 412b, and the third fastener 414c may be located within the third insulator 412c. In this way, when connected to the base plate 402, multiple fasteners (such as the first fastener 414a, the second fastener 414b, and the third fastener 414c) can achieve electrical isolation from multiple power terminals, multiple power modules, positive busbars, and negative busbars.

[0051] Figure 5 An assembly method 500 for an inverter assembly is demonstrated. This inverter assembly can provide... Figure 2 and Figure 4A specific embodiment of the inverter assembly is shown. In step 502, method 500 includes positioning power terminals into a plurality of power board slots on a power board. Power terminals are positioned into the plurality of slots on the power board by aligning a support member with the plurality of slots and extending through the power board. The support member may be connected to the power terminals; specifically, each power terminal may be connected to one end of a support member. The end not connected to the corresponding power terminal may extend through the plurality of power board slots until the power terminal is positioned within the plurality of slots on the power board. This completes the first assembly step of the inverter assembly. An example of this step is shown below. Figure 6A As shown.

[0052] See Figure 6A The first assembly step 600 shown involves positioning multiple power terminals in multiple power board slots of a power board 602. The power board 602 is configured with multiple power board slots, including a first power board slot for positioning a first power terminal 604a, a second power board slot for positioning a second power terminal 604b, and a third power board slot for positioning a third power terminal 604c. The power board 602 may also include a fourth power board slot 612d for positioning a positive busbar and a fifth power board slot 612e for positioning a negative busbar.

[0053] The power board 602 may also be configured with multiple through holes 610 for positioning multiple spacers or multiple fasteners to connect various components of the inverter assembly to the power board. The multiple spacers may include: a first spacer 608a located near the center of the power board 602, a second spacer 608b located at a first corner of the power board, a third spacer 608c located at a second corner of the power board, a fourth spacer 608d located at a third corner of the power board, and a fifth spacer 608e located at a fourth corner of the power board.

[0054] Each of the plurality of power terminals is connected to one of the plurality of support members. The plurality of power terminals may include a first power terminal 604a, a second power terminal 604b, and a third power terminal 604c. The plurality of support members may include a first support member (not shown), a second support member 606b, and a third support member 606c. The first power terminal 604a may be connected to one end of the first support member. The second power terminal 604b may be connected to one end of the second support member 606b. The third power terminal 604c may be connected to one end of the third support member 606c.

[0055] To facilitate the first inverter assembly step, a first support member (not shown) extends through a first power board slot until a first power terminal 604a is positioned in the slot. Simultaneously, a second support member 606b extends through a second power board slot until a second power terminal 604b is positioned in the slot. Furthermore, a third support member 606c extends through a third power board slot until a third power terminal 604c is positioned in the third power board slot.

[0056] like Figure 5 As shown, in step 504, method 500 includes positioning a bracket with a removable locking element on top of the power board such that power terminals are arranged within a plurality of power terminal slots in the bracket. More specifically, the power terminals are aligned with insulators in the plurality of power terminal slots within the bracket, such that one end of the power terminal surrounds one insulator and the other end surrounds another insulator located in the plurality of power terminal slots. Figure 6B An example of the second assembly step is shown.

[0057] See Figure 6B The second assembly step 601 shown: A bracket 614 with a removable locking element 616 is positioned on the surface of the power board 602. This bracket 614 can be... Figure 3 A specific embodiment of the bracket 300 shown. Figure 3 A single-sided bracket structure that can be integrated into an inverter assembly is shown. The corresponding surface of the bracket 614 is positioned to contact the surface of the power board 602. In this way, the first set of multiple locking clips disposed around the bracket 614 can connect the power board 602 to the bracket. This locking clip set may include a first locking clip 620.

[0058] When the mounting bracket 614 is positioned on the surface of the power board 602, its multiple power terminal slots are aligned with the power terminals, so that the multiple power terminals are positioned within the multiple power terminal slots. Thus, the first power terminal 604a is positioned within the first power terminal slot of the bracket, the second power terminal 604b is positioned within the second power terminal slot of the bracket, and the third power terminal 604c is positioned within the third power terminal slot of the bracket. Furthermore, the positioning of the first power terminal 604a, the second power terminal 604b, and the third power terminal 604c is such that the first power terminal, the second power terminal, and the third power terminal respectively surround two insulators located within the first power terminal slot, the second power terminal slot, and the third power terminal slot.

[0059] Specifically, one end of the first power terminal 604a surrounds the first insulator 618a, and the other end surrounds the second insulator 618b. Consequently, one end of the second power terminal 604b surrounds the third insulator 618c, and the other end surrounds the fourth insulator 618d. Furthermore, one end of the third power terminal 604c surrounds the fifth insulator 618e, and the other end surrounds the sixth insulator 618f. Any one of the first insulator 618a, the second insulator 618b, the third insulator 618c, the fourth insulator 618d, the fifth insulator 618e, and the sixth insulator 618f can serve as a single insulator among the multiple insulators contained in the support 614.

[0060] Back Figure 5 In step 506, method 500 includes positioning two busbars within two busbar slots of a bracket. This can be achieved by aligning the through-holes of each busbar with the bracket insulator and extending the support members connecting the busbars through the power board and the bracket until the two busbars are positioned within the busbar slots. As described above, one of the two busbars can be a positive busbar and the other a negative busbar; therefore, one busbar slot is the positive busbar slot and the other is the negative busbar slot.

[0061] Accordingly, the positive busbar can be positioned in the positive busbar slot as follows: align the through-hole of the positive busbar with the insulator of the bracket, and extend the support member connecting the positive busbar through the power board and the bracket until the positive busbar is positioned in the positive busbar slot. The negative busbar can be positioned in the negative busbar slot as follows: align the through-hole of the negative busbar with the insulator of the bracket, and extend the support member connecting the negative busbar through the power board and the bracket until the negative busbar is positioned in the negative busbar slot. The third inverter assembly step can be achieved as follows: align the through-holes of the positive and negative buses with the insulators located in the multiple power module slots, and partially extend the support members connecting the positive and negative buses through the positive and negative busbar slots respectively. Figure 6C An example of the third inverter assembly step is shown.

[0062] See Figure 6C The third inverter assembly step 603 shown involves aligning the through holes of the two busbars with the insulator of the bracket 614, and extending portions of the support members connected to the two busbars through the busbar slots. Specifically, the fourth support member 606d of the multiple sets of support members can be connected to the negative busbar 624, and the fifth support member 606e can be connected to the positive busbar 622. Before the fourth support member 606d partially extends into the negative busbar slot, the fifth support member 606e can partially extend into the positive busbar slot of the bracket 614.

[0063] The fifth support member 606e can partially extend through the positive busbar slot, aligning the multiple through holes of the positive busbar with the multiple insulators disposed in the multiple power module slots within the bracket 614. Specifically, the multiple insulators can be respectively disposed in the first power module slot, the second power module slot, and the third power module slot of the bracket 614. The positive busbar slot may include a first through hole 622a, a second through hole 622b, a third through hole 622c, a fourth through hole 622d, a fifth through hole 622e, and a sixth through hole (not shown). The multiple insulators may include a seventh insulator 618g, a ninth insulator 618i, a tenth insulator 618j, a twelfth insulator 618l, a thirteenth insulator 618m, and a fifteenth insulator (not shown).

[0064] The first through hole 622a can be aligned with the seventh insulator 618g located in the third power module slot; the second through hole 622b can be aligned with the ninth insulator 618i located in the third power module slot; and the third through hole 622c can be aligned with the tenth insulator 618j located in the second power module slot of the bracket 614. Furthermore, the fourth through hole 622d can be aligned with the twelfth insulator 618l located in the second power module slot; the fifth through hole 622e can be aligned with the thirteenth insulator 618m located in the first power module slot; and the sixth through hole (not shown) can be aligned with the fifteenth insulator (not shown) located in the first power module slot.

[0065] The fourth support member 606d can partially extend through the negative busbar slot, aligning the multiple through holes of the negative busbar with the multiple insulators disposed in the multiple power module slots (e.g., the first power module slot, the second power module slot, and the third power module slot) within the bracket. The negative busbar 624 may include a first through hole 624a, a second through hole 624b, and a third through hole 624c.

[0066] The plurality of insulators may include an eighth insulator 618h, an eleventh insulator 618k, and a fourteenth insulator (not shown). A first through-hole 624a may be aligned with the eighth insulator 618h located in the third power module slot, a second through-hole 624b may be aligned with the eleventh insulator 618k located in the second power module slot, and a third through-hole 622c may be aligned with the fourteenth insulator (not shown) located in the first power module slot.

[0067] Figure 6DThe fourth assembly step 605 is depicted, in which the fifth support 606e and the fourth support 606d extend fully through the power board 602 and the bracket 614, positioning the positive busbar 622 and the negative busbar 624 in the positive busbar slot and the negative busbar slot, respectively. By fully extending the fifth support 606e connected to the positive busbar 622 into the positive busbar slot, the positive busbar can surround the seventh insulator 618g in the third power module slot, the ninth insulator 618i in the third power module slot, the tenth insulator 618j in the second power module slot, the twelfth insulator 618l (positioned in the second power module slot), the thirteenth insulator 618m (positioned in the first power module slot), and the fifteenth insulator 618o (positioned in the first power module slot of the bracket 614).

[0068] Specifically, when the seventh insulator 618g passes through the first through-hole 622a, the positive busbar 622 surrounds it; when the ninth insulator 618i passes through the second through-hole 622b, the positive busbar surrounds it; and surrounds the tenth insulator 618j, which extends through the third through-hole 622c. Furthermore, the positive busbar 622 surrounds the twelfth insulator 618l when it passes through the fourth through-hole 622c, surrounds the thirteenth insulator 618m when it passes through the fifth through-hole 622e, and surrounds the fifteenth insulator 618o, which extends through the sixth through-hole 622f.

[0069] Similarly, the fourth support member 606d connecting the negative busbar 624 extends completely through the negative busbar slot, enabling the negative busbar to surround the eighth insulator 618h in the third power module slot, the eleventh insulator 618k in the second power module slot, and the fourteenth insulator 618n in the first power module slot. More specifically: when the eighth insulator 618h protrudes through the first through-hole 624a, the negative busbar 624 surrounds it; when the eleventh insulator 618k protrudes through the second through-hole 624b, the negative busbar surrounds it; and surrounds the fourteenth insulator 618n—which extends through the third through-hole 624c.

[0070] Therefore, the first overlapping section 623a of the positive busbar 622 and the negative busbar 624 is positioned between the first power module slot and the second power module slot on one side of the positive and negative busbars, and between the third power module slot on the other side. Furthermore, the second overlapping section 623b of the positive busbar 622 and the negative busbar 624 is located between the first power module slot and the second power module slot. Thus, the first power module slot is located on one side of the positive busbar 622 and the negative busbar 624, and the second power module slot is located on the other side of the positive busbar 622 and the negative busbar 624.

[0071] like Figure 5As shown, in step 508, method 500 includes removing a removable locking element from the bracket and positioning the locking element in the central region of the bracket. The removable locking element 301 can be manually removed by applying pressure to separate it from the bracket. After separating the removable locking element from the side of the bracket, it can be positioned above the assembled positive and negative busbars within the central region of the bracket. More specifically, the removable locking element can be positioned above a first overlapping section of the positive and negative busbars.

[0072] Positioning of the removable locking element is achieved by engaging its end with a pair of locking slots. One locking slot is located on one side of the bracket, and the other is located on the opposite side of the bracket. Thus, the removable locking element can be connected to the bracket by means of locking latches provided on the opposite surfaces of the bracket.

[0073] Back Figure 6D As shown, the fourth step 605 of inverter assembly includes positioning a removable locking element 616 on top of the positive bus 622 and negative bus 624 in the central region of the bracket 614. The removable locking element 616 can be positioned on a first overlapping section 623a of the positive bus 622 and negative bus 624. One end of the locking element is connected to one side of the bracket 614, and the other end is connected to the other side of the bracket.

[0074] Back Figure 5 In step 510, method 500 includes positioning a power module within a plurality of power module slots in a bracket. As described above, the plurality of power module slots includes a first power module slot, a second power module slot, and a third power module slot. Positioning the power module within the plurality of power module slots may include aligning an insulator of the bracket with a through-hole on the surface of the power module, and extending the insulator through the through-hole until the power module contacts the bracket and the power board. The first power module may be positioned by aligning an insulator within a first power module slot with a through-hole on the surface of the first power module, and extending the insulator within the first power module slot until the first power module, the power board, and the bracket contact each other.

[0075] The positioning method for the second power module is as follows: align the insulator inside the second power module slot with the through-hole on the surface of the second power module, and extend the insulator inside the slot until the second power module, power board, and bracket contact each other. The positioning method for the third power module is as follows: align the insulator inside the third power module slot with the through-hole on the surface of the third power module, and extend the insulator inside the slot until the third power module, power board, and bracket contact each other. In this way, the first power module can be positioned in the first power module slot of the bracket, the second power module can be positioned in the second power module slot of the bracket, and the third power module can be positioned in the third power module slot of the bracket, such as... Figure 6EAs shown. In addition, the first power module 626, the second power module 628 and the third power module 630 can be connected to the bracket via multiple locking clips.

[0076] See Figure 6E The fifth inverter assembly step 607 is shown, at which point each power module has been positioned in its corresponding power module slot. This step includes: the first power module 626 being positioned in the first power module slot, the second power module 628 being positioned in the second power module slot, and the third power module 630 being positioned in the third power module slot. The surface of the first power module 626 includes a first through hole 626a, a second through hole 626b, a third through hole 626c, a fourth through hole 626d, and a fifth through hole 626e.

[0077] The positioning of the first power module 626 is such that the first through hole 626a can be aligned with and surround the first insulator 618a, and the second through hole 626b can be aligned with and surround the second insulator 618b. Furthermore, the positioning of the first power module 626 is such that: the third through hole 626c can be aligned with and surround the fifteenth insulator 618o; the fourth through hole 626d can be aligned with and surround the fourteenth insulator 618n; and the fifth through hole 626e can be aligned with and surround the thirteenth insulator 618m.

[0078] The surface of the second power module 628 includes a first through hole 628a, a second through hole 628b, a third through hole 628c, a fourth through hole 628d, and a fifth through hole 628e. The second power module 628 is positioned such that the first through hole 628a can be aligned with and surround the third insulator 618c, and the second through hole 628b can be aligned with and surround the fourth insulator 618d. Furthermore, the second power module 628 is positioned such that: the third through hole 628c can be aligned with and surround the tenth insulator 618j; the fourth through hole 628d can be aligned with and surround the eleventh insulator 618k; and the fifth through hole 628e can be aligned with and surround the twelfth insulator 618l.

[0079] The surface of the third power module 630 includes a first through-hole 630a, a second through-hole 630b, a third through-hole 630c, a fourth through-hole 630d, and a fifth through-hole 630e. The third power module 630 is positioned such that: the first through-hole 630a can be aligned with and surround the fifth insulator 618e; the second through-hole 630b can be aligned with and surround the sixth insulator 618f. Furthermore, the third power module 630 is positioned such that: the third through-hole 630c can be aligned with and surround the seventh insulator 618g; the fourth through-hole 630d can be aligned with and surround the eighth insulator 618h; and the fifth through-hole 630e can be aligned with and surround the ninth insulator 618i.

[0080] The first power module 626, the second power module 628, and the third power module 630 can all be connected to the bracket 614 via multiple locking clips. For example, the multiple locking clips may include a second locking clip 632, which connects the third power module 630 to the bracket 614. In step 512, method 500 includes passing multiple fasteners through multiple through holes on the surface of the power board, positioning the fasteners inside an insulator, thereby connecting the power terminals, two busbars, and the power modules to the power board. More specifically, the multiple fasteners may be positioned within multiple insulators to connect the first power terminal, the second power terminal, the third power terminal, the positive busbar, the negative busbar, the first power module, the second power module, and the third power module to the power board. Furthermore, the multiple fasteners can connect the first power module, the second power module, and the third power module to a base plate. Method 500 then ends.

[0081] Figure 7 A perspective view 700 shows the assembled power inverter assembly. The assembly process can be referenced... Figure 7 The method is implemented as follows. The assembled power inverter assembly includes: a power board 702 connected to a first power module 706, a second power module 708, and a third power module 710; and a positive bus, a negative bus, a first power terminal, a second power terminal, and a third terminal. According to an embodiment of the present invention, the first power module 706, the second power module 708, the third power module 710, the positive bus, the negative bus, the first power terminal, the second power terminal, and the third power terminal are all positioned, centered, and insulated by a bracket 704.

[0082] Each power module integrates two locating pins near the signal connector to facilitate insertion of the signal connector into the power board 702. The power board has two through holes for locating these two locating pins. For example, the first locating pin 712a can pass through one through hole of the power board 702, and the second locating pin 712b can pass through the other through hole of the power board. The first locating pin 712a and the second locating pin 712b together facilitate the mounting of the signal connector on the power board 702.

[0083] The advantage of integrating detachable locking elements into the bracket is that, due to the bracket's multiple locking and insulation functions, it can achieve the positioning, centering, and insulation of various components of the power module equipment, thereby reducing the number of equipment components and assembly steps. This, in turn, can reduce the error rate and shorten the assembly time during the assembly process of power module equipment (such as inverter components).

[0084] The present invention also provides a bracket for a power module device, characterized in that: it includes a plurality of terminal slots for positioning and centering power terminals, two busbar slots for positioning and centering two busbars, a plurality of module slots for positioning and centering power modules, for connecting a plurality of terminals and two busbars, and a plurality of locking slots for connecting a power board to the bracket; a plurality of insulators are disposed in the plurality of power terminal slots and the plurality of power module slots, each insulator positioning a fastener that connects the plurality of power terminals and the two busbars to the heat sink of the power module device; a plurality of locking clips are integrated on the sides of the plurality of power terminal slots, the periphery of both ends of the bracket, and the surface of the bracket; and a removable locking element located at the edge of the bracket (before disassembly).

[0085] In a first embodiment of the system, the system further includes: a first portion in the form of a truncated rounded rectangle; a second portion connected to one side of the first portion and also in the form of a truncated rounded rectangle (the truncated surface is located on the opposite side of the second portion); a rectangular third portion connected to the second portion; and a stepped fourth portion connected to the third portion. In a second embodiment of the system (optionally including the first embodiment), the length and width of the first portion are both greater than those of the second, third, and fourth portions; the length of the second portion is greater than that of the third portion but its width is less than that of the third portion; the length of the fourth portion is greater than that of the second portion but its width is less than that of the second and third portions.

[0086] In a third embodiment of the system (optionally including one or both of the first and second embodiments), the first portion has two power terminal slots: one located at one end of the portion and the other at the other end. In a fourth embodiment of the system (optionally including one or more of the first to third embodiments), a power terminal slot extends from the fourth portion into the region of the third portion. In a fifth embodiment of the system (optionally including one or all of the first to fourth embodiments), the plurality of power terminal slots are generally rectangular, and supports extend inward at both ends of each power terminal slot to position insulator pairs located within the respective power terminal slots.

[0087] In a sixth embodiment of the system (optionally including one or more of the first to fifth embodiments), two power module slots are spaced apart in the first part, such that one power module is spaced and aligned with a power terminal slot at one end of the first part, and the other power module is spaced and aligned with a power terminal slot at the other end of the first part. In a seventh embodiment of the system, one or more of the first to sixth embodiments may be included, wherein one power module slot extends from the third part to the second part and is aligned with a power terminal slot located in the fourth part, and the plurality of power module slots are generally rounded rectangles with dimensions larger than the plurality of power terminal slots.

[0088] In an eighth embodiment of the system, optionally including one or more of the first to seventh embodiments, the bracket extends to one side of each power module slot to position three insulators within the respective power module slot. In a ninth embodiment of the system, optionally including one or more of the first to eighth embodiments, two busbar slots are generally circular and located near both ends of the second portion of the bracket, such that a power terminal slot is spaced between the two busbar slots. In a tenth embodiment of the system (optionally including one or more of the first to ninth embodiments), the removable locking element is manufactured using the same mold and the same materials as the bracket.

[0089] This disclosure also provides a method for assembling a power module device, comprising: positioning power terminals into a plurality of power board slots of a power board; positioning a bracket with a removable locking element above the power board, such that the power terminals are arranged in the plurality of power terminal slots of the bracket; positioning two busbars into two busbar slots of the bracket; removing the removable locking element from the bracket and positioning the locking element in the central region of the bracket; positioning the power module in the plurality of power module slots of the bracket, and having a plurality of fasteners pass through through holes on the surface of the power board, such that the fasteners are positioned within an insulator to connect the power terminals, the two busbars, and the power module to a power board. In a first embodiment of the method, positioning the power terminals into the plurality of slots of the power board includes: arranging a support member to align with the plurality of slots of the power board, the support member being connected to the power terminals and extending through the power board.

[0090] In a second embodiment of the method (optionally including the first embodiment), positioning two busbars to two busbar slots of the bracket includes: aligning the through-hole of each busbar with the bracket insulator, and extending a support connecting the two busbars through the power board and the bracket until the two busbars are positioned within the two busbar slots. In a third embodiment of the method (optionally including one or both of the first and second embodiments), positioning the power module within a plurality of power module slots of the bracket includes: aligning the insulator with through-holes positioned on the surface of the power module, and extending the insulator through the through-holes until the power module contacts the bracket and the power board.

[0091] This disclosure also provides a support structure for an inverter assembly, including: a power board having multiple power board slots for positioning a first power terminal, a second power terminal, a third power terminal, a positive bus, a negative bus, a first power module, a second power module, and a third power module; a bracket with a removable locking element, comprising: a first power terminal slot located at one end of a first portion of the bracket; a second power terminal slot located at the other end of the first portion of the bracket; a third power terminal slot located between a third portion and a fourth portion of the bracket; a first power module slot spaced apart from the first power terminal slot on one side and from the second power module slot on the other side; a second power module slot spaced apart from the second power terminal slot on the other side; and a third power module slot spaced apart inside the third power terminal slot and located in the second and third portions of the bracket. Within the bracket, the positive busbar slot is located on one side of the third power module slot, and the negative busbar slot is located on the other side of the third power module slot within the second part of the bracket. Multiple insulators are also included for positioning multiple fasteners, which are respectively positioned within the first power terminal slot, the second power terminal slot, the third power terminal slot, the first power module slot, the second power module slot, and the third power module slot. Multiple locking slots and multiple locking clips are used to connect the first power terminal, the second power terminal, the third power terminal, the positive busbar, the negative busbar, the first power module, the second power module, and the third power module to the bracket. Finally, a base plate serving as a heat sink is connected to the first power module, the second power module, the third power module, the positive busbar, the negative busbar, the first power terminal, the second power terminal, the third power terminal, and the power board via multiple fasteners.

[0092] In a first embodiment of the system, the bracket is located on the surface of the power board. In a second embodiment of the system (optionally including the first embodiment), the first power terminal, the second power terminal, and the third power terminal are respectively located in the first power terminal slot, the second power terminal slot, and the third power terminal slot of the bracket, and surround two insulators located in the aforementioned slots. In a third embodiment of the system (optionally including the first and / or the second embodiment), the positive busbar is positioned in the positive busbar slot, and the negative busbar is positioned in the negative busbar slot, such that the positive and negative buses together surround multiple insulators located in the first power module slot, the second power module slot, and the third power module slot. In a fourth embodiment of the system (optionally including one or more of the first to third embodiments), the first power module, the second power module, and the third power module are respectively positioned in the first power module slot, the second power module slot, and the third power module slot, and are connected to the base plate by fasteners.

[0093] Figure 2 , 3Tables 4, 6A-6E, and 7 illustrate example configurations of the relative positioning of the components. If the components in the illustrations are in direct contact or directly connected, then in at least one example, such elements can be referred to as directly contacted or directly connected, respectively. Similarly, if the elements are adjacent or adjacent, then in at least one example, they can be referred to as adjacent or adjacent, respectively. For example, components that are in face-to-face contact can be called face-to-face contact; similarly, elements separated only by a gap and without other components sandwiched between them can be described in this way in at least one example. As another example, elements arranged vertically, on opposite sides, or adjacent to each other in the illustrations can be described accordingly in relation to each other. Furthermore, as shown in the figures, in at least one example, the topmost element or point of a component can be called the "top" of that component, and the bottommost element or point can be called the "bottom" of that component. The terms "top / bottom," "upper / lower," and "above / below" used in this document are all based on the vertical axis of the illustration and are used to describe the relative positional relationships between the elements in the illustrations. For example, an element located above other elements is vertically positioned above them. To give another example, the shape of an element in the illustration can be described as having a specific form (e.g., circle, straight line, plane, curve, rounded corner, chamfer, slant, etc.). Furthermore, in at least one example, overlapping elements can be referred to as overlapping elements or mutually overlapping. Moreover, elements located inside or outside another element can be described accordingly.

[0094] The above description is merely to illustrate the basic principles of the described embodiments. Given that many modifications and variations will readily occur to those skilled in the art, the embodiments are not intended to be limited to the precise structures and processes shown and described herein. Therefore, all applicable modifications and equivalents are to be considered to fall within the scope of the embodiments as defined by the following claims.

Claims

1. A bracket for a power module device, comprising: Multiple power terminal slots, the power terminal slots being used to position and center multiple power terminals; Two busbar slots are provided for positioning and centering the two busbars. Multiple power module slots, the power module slots being used for positioning and centering power modules; Multiple locking slots are provided for connecting the multiple power terminals, the two busbars and the multiple power boards to the bracket. Multiple insulators are disposed in multiple power terminal slots and multiple power module slots, wherein each insulator is positioned by a fastener that connects the multiple power terminals and the two busbars to the heat sink of the power module device. Multiple locking clips are integrated into the sides of the multiple power terminal slots, the periphery of both ends of the bracket, and the surface of the bracket. as well as A removable locking element is located at the edge of the bracket before disassembly.

2. The bracket for a power module device as claimed in claim 1, further comprising: The first part is a truncated rounded rectangle; The second part is connected to the first part on one side and is a truncated rounded rectangle with the truncated surface located on the opposite side of the second part. The third part is rectangular and connected to the second part; as well as The fourth part, which is shaped like a stadium, is connected to the third part.

3. The bracket for a power module device as claimed in claim 2, wherein the length and width of the first part are both greater than the second part, the third part and the fourth part, the length of the second part is greater than the third part but the width is less than the third part, and the length of the fourth part is greater than the second part but the width is less than the second part and the third part.

4. The bracket for a power module device as claimed in claim 3, wherein the first portion includes two power terminal slots, one power terminal slot being located at one end of the first portion and the other power terminal slot being located at the other end of the first portion.

5. The bracket for a power module device as claimed in claim 4, wherein one of the power terminal slots extends from the fourth portion to a portion of the third portion.

6. The bracket for a power module device as claimed in claim 5, wherein the plurality of power terminal slots are generally rectangular, and the bracket extends into the terminal slot at both ends of each power terminal slot to position a pair of insulators located within the respective terminal slot.

7. The bracket for a power module device as claimed in claim 3, wherein two of the plurality of power module slots are spaced apart from each other and located in the first portion, such that one power module is spaced apart from and aligned with a power terminal slot at one end of the first portion, and the other power module is spaced apart from and aligned with another power terminal slot at the other end of the first portion.

8. The bracket for a power module device as claimed in claim 7, wherein one power module slot extends from the third portion to the second portion and is aligned with a power terminal slot located in the fourth portion, and the plurality of power module slots are generally rounded rectangles and are larger than the plurality of power terminal slots.

9. The bracket for a power module assembly as claimed in claim 8, wherein the bracket extends inward on one side of each power module slot to position three insulators within the respective power module slot.

10. The bracket for a power module device as claimed in claim 3, wherein the two busbars are generally circular and located near both ends of the second portion, such that a power terminal slot is provided between the two busbars at an interval.

11. The bracket for a power module device as claimed in claim 1, wherein the removable locking element is manufactured using the same mold and the same material as the bracket.

12. A method for assembling a power module device, comprising: Position the power terminals into multiple power board slots on the power board; Position a bracket with a removable locking element above the power board, such that the power terminals are arranged in the plurality of power terminal slots of the bracket; The two busbars are positioned in the two busbar slots of the bracket; Remove the removable locking element from the bracket and position the removable locking element in the central region of the bracket; The power modules are positioned in multiple power module slots on the bracket; as well as Multiple fasteners are passed through through holes on the surface of the power board, positioning the fasteners within the insulator, thereby connecting the power terminals, the two busbars, and the power module to the power board.

13. The method of claim 12, wherein positioning the power terminal to the plurality of power board slots comprises: A support member is arranged to align with the plurality of power board slots, the support member is coupled to the power terminals, and the support member extends through the power board.

14. The method of claim 12, wherein positioning the two busbars in the two busbar slots of the bracket comprises: Align the through holes of each busbar with the insulator of the bracket, and extend the support members connected to the two busbars through the power board and the bracket until the two busbars are positioned in the two busbar slots.

15. The method of claim 12, wherein positioning the power module within the plurality of power module slots of the bracket comprises: Align the insulator with the through hole positioned on the surface of the power module, and extend the insulator through the through hole until the power module contacts the bracket and the power board.

Images