Power module, motor controller, electric drive assembly and vehicle

Abstract

The embodiment of the application discloses a power module, a motor controller, an electric drive assembly and a vehicle, the first pole terminal comprises a second structure part, the second pole terminal comprises a fourth structure part, the plane where the second structure part is located intersects with the plane where the power module body is located, the plane where the fourth structure part is located intersects with the plane where the power module body is located, the second structure part and the fourth structure part are located in different planes, which is conducive to realizing the terminal structure that the first pole terminal and the second pole terminal exist overlapping surfaces at the positions of the second structure part and the fourth structure part, since the current directions corresponding to the first pole terminal and the second pole terminal are opposite, the parasitic inductance at the positions of the second structure part and the fourth structure part is reduced, so that the overall parasitic inductance of the power module is reduced, and the performance of the power module is improved.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to Chinese Patent Application No. 202510523153.2, entitled "Power Module and Electric Drive Device", filed on April 23, 2025, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to the field of power electronics technology, and more particularly to a power module, a motor controller, an electric drive assembly, and a vehicle. Background Technology

[0004] The power module is one of the important components of a vehicle and has a wide range of applications.

[0005] Existing power modules suffer from high parasitic inductance. Summary of the Invention

[0006] The present invention provides a power module, a motor controller, an electric drive assembly, and a vehicle to reduce the parasitic inductance of the power module and improve its performance.

[0007] According to one aspect of the present invention, a power module is provided, optionally including a power module body, a first terminal and a second terminal, wherein the first terminal includes a second structural portion and the second terminal includes a fourth structural portion;

[0008] The plane containing the second structural part intersects with the plane containing the power module body, and the plane containing the fourth structural part intersects with the plane containing the power module body. The second and fourth structural parts are located on different planes.

[0009] Optionally, the projection of the second structural part onto the plane containing the fourth structural part overlaps with the fourth structural part at least partially.

[0010] Optionally, the second and fourth structural parts are sheet-like structures.

[0011] Optionally, both the first and second terminals are DC terminals.

[0012] Optionally, the plane containing the second structural part is parallel to the plane containing the fourth structural part.

[0013] Optionally, the first end part includes a first structural part connected to the second structural part, the second end part includes a third structural part connected to the fourth structural part, the plane where the first structural part is located intersects the second structural part, the plane where the third structural part is located intersects the fourth structural part, the first structural part is connected to the power module body, and the third structural part is connected to the power module body.

[0014] Optionally, the first structural part is welded to the power module body, and / or the third structural part is welded to the power module body.

[0015] Optionally, the plane containing the first structural part is parallel to the plane containing the third structural part.

[0016] Optionally, the spacing between the second and fourth structural parts is 1mm-50mm.

[0017] Optionally, the first structural portion extends in a first direction from the position where it is connected to the second structural portion, and the third structural portion extends in a first direction from the position where it is connected to the fourth structural portion.

[0018] Optionally, the first end part includes at least two first structural parts, and the second end part includes at least two third structural parts. The first structural parts and the third structural parts are alternately arranged along a second direction, and the second direction intersects with the first direction.

[0019] Optionally, the second structural part extends in a third direction from the position where it is connected to the first structural part, and the fourth structural part extends in a fourth direction from the position where it is connected to the third structural part.

[0020] The extension distance of the second structural part is not the same as that of the fourth structural part.

[0021] Optionally, the third-direction and the fourth-direction are the same.

[0022] Optionally, the first end part further includes a fifth structural part, which is connected to the second structural part; the second end part further includes a sixth structural part, which is connected to the fourth structural part.

[0023] The fifth and sixth structural parts are located on different planes.

[0024] Optionally, the fifth structural part extends in a fifth direction from the connection position with the second structural part, and the sixth structural part extends in a fifth direction from the connection position with the fourth structural part.

[0025] Optionally, the power module body includes a first connection layer and a second connection layer. The first connection layer includes a first welding area corresponding to the first structural part, and the first structural part is welded to the first connection layer in the first welding area. The second connection layer includes a second welding area corresponding to the third structural part, and the third structural part is welded to the second connection layer in the second welding area.

[0026] Optionally, the first connecting layer may also include a first cutout area corresponding to the first welding area;

[0027] The second connecting layer has a second hollow area corresponding to the second welding area.

[0028] Optionally, a third cutout area corresponding to the second welding area is provided on the first connecting layer, and / or,

[0029] The second connecting layer has a fourth hollow area corresponding to the first welding area.

[0030] Optionally, the power module further includes a power device layer located between the first connection layer and the second connection layer. The power device layer has at least one bridge arm, which includes an upper bridge arm and a lower bridge arm. The first end of the upper bridge arm is connected to the first connection layer, the second end of the upper bridge arm is connected to the first end of the corresponding lower bridge arm, and the second end of the lower bridge arm is connected to the second connection layer.

[0031] Optionally, the first welding area and the second welding area are misaligned along the first direction, and the first welding area and the second welding area are arranged alternately along the second direction, with the first direction and the second direction intersecting.

[0032] Optionally, the first structural part and the third structural part are misaligned along the first direction.

[0033] Optionally, each of the first structural parts is connected by a second structural part;

[0034] And / or, each third structural part is connected by a fourth structural part.

[0035] According to another aspect of the present invention, a motor controller is provided, including a power module according to any embodiment of the present invention.

[0036] According to another aspect of the present invention, an electric drive assembly is provided, including a motor controller according to any embodiment of the present invention.

[0037] According to another aspect of the present invention, a vehicle is provided, including an electric drive assembly according to any embodiment of the present invention.

[0038] The power module, motor controller, electric drive assembly, and vehicle of this invention, by setting a first terminal to include a second structural part and a second terminal to include a fourth structural part, wherein the plane of the second structural part intersects with the plane of the power module body, and the plane of the fourth structural part intersects with the plane of the power module body, and the second and fourth structural parts are located on different planes, it is beneficial to realize a terminal structure in which the first and second terminals have overlapping surfaces at the positions of the second and fourth structural parts. Since the current directions corresponding to the first and second terminals are opposite, the parasitic inductance at the positions of the second and fourth structural parts is reduced, thereby reducing the overall parasitic inductance of the power module and improving the performance of the power module.

[0039] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0040] 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.

[0041] Figure 1 This is a schematic diagram of the structure of a power module provided in an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram of another power module provided in an embodiment of the present invention;

[0043] Figure 3 This is a schematic diagram of another power module provided in an embodiment of the present invention;

[0044] Figure 4 This is a top view of a power module provided in an embodiment of the present invention;

[0045] Figure 5 This is a cross-sectional view of a power module provided in an embodiment of the present invention;

[0046] Figure 6 This is a structural diagram of a portion of the structure in the first connecting layer;

[0047] Figure 7 This is a structural diagram of a portion of the second connecting layer;

[0048] Figure 8 This is a schematic diagram of another power module provided in an embodiment of the present invention;

[0049] Figure 9 This is a schematic diagram of the power module structure in related technologies;

[0050] Figure 10 This is a schematic diagram of another power module provided in an embodiment of the present invention;

[0051] Figure 11 This is a schematic diagram of the structure of a motor controller provided in an embodiment of the present invention. Detailed Implementation

[0052] 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 should fall within the scope of protection of the present invention.

[0053] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0054] Figure 1 This is a schematic diagram of the structure of a power module provided in an embodiment of the present invention, for reference. Figure 1 The power module includes a power module body 100, a first terminal and a second terminal, which are respectively connected to the power module body 100. The first terminal includes a second structural part 220 and the second terminal includes a fourth structural part 320. The plane where the second structural part 220 is located intersects the plane where the power module body 100 is located, and the plane where the fourth structural part 320 is located intersects the plane where the power module body 100 is located. The second structural part 220 and the fourth structural part 320 are located on different planes.

[0055] By setting the first terminal to include a second structural part and the second terminal to include a fourth structural part, the plane where the second structural part is located intersects with the plane where the power module body is located, and the plane where the fourth structural part is located intersects with the plane where the power module body is located. The second structural part and the fourth structural part are located on different planes, which is beneficial to realize a terminal structure in which the first terminal and the second terminal have overlapping surfaces at the positions of the second structural part and the fourth structural part. Since the current directions corresponding to the first terminal and the second terminal are opposite, the parasitic inductance at the positions of the second structural part and the fourth structural part is reduced, thereby reducing the overall parasitic inductance of the power module and improving the performance of the power module.

[0056] Combined with appendix Figure 1 , 2As can be seen from sections 4 and 11, by way of example, both the second structural part 220 and the fourth structural part 320 are sheet-like structures, each corresponding to the plane in which it is located. Specifically, those skilled in the art will understand that the sheet-like structure mentioned herein corresponding to the plane in which it is located means that, due to reasons such as process technology conditions, a portion of the sheet-like structure may deviate from that plane. Those skilled in the art will also understand that the sheet-like structure mentioned herein is a three-dimensional structure with thickness, such as a metal busbar, or a copper busbar.

[0057] The power module body 100 may include a power conversion circuit, such as an inverter circuit. The power module body 100 may include a printed circuit board (PCB) comprising multiple conductive layers, with insulating layers disposed between adjacent conductive layers. Power devices of the power module body 100 may be embedded in the PCB. Optionally, the power module body 100 includes a drive circuit, such as a half-bridge drive circuit. In some embodiments, the power module body 100 includes a three-phase full-bridge drive circuit.

[0058] Those skilled in the art will understand that the power module body described herein is a multi-layer circuit board including power conversion circuitry, i.e., a multi-layer circuit board including drive circuitry. The plane containing the power module body can be understood as any plane parallel to the plane containing any layer of the multi-layer circuit board.

[0059] Optionally, both the first and second terminals are DC terminals. The power module body 100 is connected to the first terminal of the power supply via the first terminal, and the power module body 100 is connected to the second terminal of the power supply via the second terminal. For example, the first terminal may be a positive terminal, the second terminal a negative terminal, the first terminal of the power supply being the positive terminal, and the second terminal the negative terminal; or the first terminal may be a negative terminal, the second terminal a positive terminal, the first terminal being the negative terminal, and the second terminal the positive terminal. The first and second terminals each comprise a conductive material, such as copper, to achieve conductivity.

[0060] In this embodiment of the invention, the first terminal includes a second structural part 220. In some embodiments, the second structural part 220 is directly connected to the power module body 100. In other embodiments, the first terminal may also include other structural parts, and the second structural part 220 is connected to the power module body 100 through other structural parts.

[0061] The second extreme part includes a fourth structural part 320. In some embodiments, the fourth structural part 320 is directly connected to the power module body 100. In other embodiments, the second extreme part may also include other structural parts, and the second structural part 320 is connected to the power module body 100 through other structural parts.

[0062] Figure 1 The diagram schematically illustrates the current direction when the first terminal is the positive terminal, as indicated by the black arrow at the first terminal; and the current direction when the second terminal is the negative terminal, as indicated by the red arrow at the second terminal. (Reference) Figure 1 Current can flow from the positive terminal of the power supply to the second structural section 220, and then from the second structural section 220 to the power module body 100. Current flows from the power module body 100 to the fourth structural section 320, and then to the negative terminal of the power supply.

[0063] When the first terminal is the negative terminal and the second terminal is the positive terminal, current can flow from the positive terminal of the power supply to the fourth structural section 320, and then from the fourth structural section 320 to the power module body 100. Current can flow from the power module body 100 to the second structural section 220, and then to the negative terminal of the power supply. That is, the current directions corresponding to the first terminal and the second terminal are opposite.

[0064] In this embodiment of the invention, the second structural part 220 and the fourth structural part 320 are located on different planes, which makes it easy to realize a terminal structure in which the second structural part 220 and the fourth structural part 320 have overlapping surfaces, thereby increasing the overlapping area of ​​the first terminal and the second terminal, reducing the parasitic inductance of the power module, and improving the performance of the power module.

[0065] Optionally, the projection of the second structural portion 220 onto the plane containing the fourth structural portion 320 at least partially overlaps with the fourth structural portion 320. That is, the orthographic projection of the second structural portion 220 onto the plane containing the fourth structural portion 320 is at least partially located on the fourth structural portion 320, resulting in an overlapping surface between the second structural portion 220 and the fourth structural portion 320. This increases the overlapping area of ​​the first and second terminals, reduces the parasitic inductance of the power module, and improves the performance of the power module.

[0066] Optionally, the plane containing the second structural part 220 is parallel to the plane containing the fourth structural part 320.

[0067] In this embodiment, the plane where the second structural part 220 is located is parallel to the plane where the fourth structural part 320 is located, which makes it easier for the orthographic projection of the second structural part 220 on the plane where the fourth structural part 320 is located to have a larger overlapping area with the fourth structural part 320. In this way, the overlapping area of ​​the first terminal and the second terminal can be further increased, and the parasitic inductance of the power module can be further reduced.

[0068] Optionally, the distance between the second structural portion 220 and the fourth structural portion 320 is 1mm-50mm. This allows for a smaller distance between the second structural portion 220 and the fourth structural portion 320, thereby further reducing the parasitic inductance at the locations of the second structural portion 220 and the fourth structural portion 320; in addition, it ensures that the second structural portion 220 and the fourth structural portion 320 will not come into contact, preventing short circuits between them and ensuring the reliability of the power module operation.

[0069] For example, the distance between the second structural portion 220 and the fourth structural portion 320 is 1mm, 8mm, 10mm, 13mm, 20mm, 26mm, 30mm, 38mm, 40mm, 42mm or 50mm.

[0070] Figure 2 This is a schematic diagram of another power module provided in an embodiment of the present invention, for reference. Figure 2 Optionally, the first extreme part includes a first structural part 210 connected to the second structural part 220, and the second extreme part includes a third structural part 310 connected to the fourth structural part 320. The plane where the first structural part 210 is located intersects with the second structural part 220, and the plane where the third structural part 310 is located intersects with the fourth structural part 320. The first structural part 210 is connected to the power module body 100, and the third structural part 310 is connected to the power module body 100.

[0071] Combined with appendix Figure 2 , 3 As can be seen from points 4, 8, and 11, the first structural part 210 and the third structural part 310 are sheet-like structures, each corresponding to the plane in which it is located.

[0072] In this embodiment, the first structural portion 210 and the second structural portion 220 are connected, which can be achieved by the first structural portion 210 and the second structural portion 220 contacting each other without any other structure between them. In some embodiments, the first structural portion 210 and the second structural portion 220 are an integral structure. In other embodiments, other structures can be provided between the first structural portion 210 and the second structural portion 220. For example, a first connecting structure can be provided between the first structural portion 210 and the second structural portion 220, and the first structural portion 210 and the second structural portion 220 are indirectly connected through the first connecting structure. The first connecting structure can include a curved surface structure to make the connection between the first structural portion 210 and the second structural portion 220 smoother. By providing the first terminal piece, which also includes the first structural portion 210, and connecting the first structural portion 210 to the power module body 100, the area of ​​the connection surface between the power module body 100 and the first terminal piece can be increased, thereby ensuring the reliability of the connection between the first terminal piece and the power module body 100, and at the same time, it helps to reduce the contact resistance and parasitic inductance.

[0073] In this embodiment, the third structural part 310 and the fourth structural part 320 are connected, which can be in contact between the third structural part 310 and the fourth structural part 320 without any other structure between them. In some embodiments, the third structural part 310 and the fourth structural part 320 are an integral structure. In other embodiments, other structures can be provided between the third structural part 310 and the fourth structural part 320, such as a second connecting structure provided between the third structural part 310 and the fourth structural part 320, which indirectly connects the third structural part 310 and the fourth structural part 320. This second connecting structure can include a curved surface structure, making the connection between the third structural part 310 and the fourth structural part 320 smoother. By providing the second terminal also including the third structural part 310, and connecting the third structural part 310 to the power module body 100, the area of ​​the connection surface between the power module body 100 and the second terminal can be increased, thereby ensuring the reliability of the connection between the second terminal and the power module body 100, and at the same time, it helps to reduce the contact resistance and parasitic inductance.

[0074] When the first terminal is the positive terminal, current can flow from the positive terminal of the power supply to the second structural section 220, then from the second structural section 220 to the first structural section 210, and then from the first structural section 210 to the power module body 100. Figure 2 The diagram schematically illustrates the current direction when the first terminal is the positive terminal, as indicated by the black arrow at the first terminal. When the second terminal is the negative terminal, the current flows from the power module body 100 to the third structural section 310, then from the third structural section 310 to the fourth structural section 320, and finally to the negative terminal of the power supply. Figure 1 The diagram schematically illustrates the current direction when the second terminal is the negative terminal, as indicated by the red arrow at the second terminal. When the first terminal is the negative terminal, the current flows from the power module body 100 to the first structural section 210, then from the first structural section 210 to the second structural section 220, and finally to the negative terminal of the power supply. When the second terminal is the positive terminal, the current flows from the positive terminal of the power supply to the fourth structural section 320, then from the fourth structural section 320 to the third structural section 310, and finally from the third structural section 310 back to the power module body 100. In other words, the current directions corresponding to the first and second terminals are opposite.

[0075] Optionally, the first structural part 210 is welded to the power module body 100, and / or the third structural part 310 is welded to the power module body 100. In this way, the connection between the first terminal and the power module body 100, as well as the connection between the second terminal and the power module body 100, are achieved through welding. This connection method is simple, ensures a strong connection, and improves the reliability of the power module.

[0076] Optionally, the plane containing the first structural part 210 is parallel to the plane containing the third structural part 310.

[0077] Specifically, the first structural portion 210 and the third structural portion 310 can be welded to the power module body 100, for example, by welding the first structural portion 210 to a copper block, the conductive layer of the first structural portion 210 and the power module body 100 is connected. Similarly, by welding the third structural portion 310 to another copper block, the conductive layer of the third structural portion 310 and the power module body 100 is connected, making the plane where the first structural portion 210 is located parallel to the plane where the third structural portion 310 is located. By including the first structural portion 210 in the first terminal, and connecting the first structural portion 210 to the power module body 100, the connection area between the first terminal and the power module body 100 is increased, thereby further reducing the parasitic inductance of the power module. The second terminal also includes the third structural portion 310, and connecting the second terminal to the power module body 100 increases the connection area between the second terminal and the power module body 100, thereby further reducing the parasitic inductance of the power module.

[0078] Taking an example where the planes containing the first structural portion 210 and the third structural portion 310 are parallel to the horizontal plane, the plane containing the second structural portion 220 intersects the horizontal plane, and the plane containing the fourth structural portion 320 also intersects the horizontal plane. In some embodiments, the angle between the plane containing the second structural portion 220 and the plane containing the first structural portion 210 is greater than 0 degrees and less than 180 degrees. The angle between the plane containing the fourth structural portion 320 and the plane containing the third structural portion 310 is greater than 0 degrees and less than 180 degrees. This makes it easier for the orthographic projection of the second structural portion 220 onto the plane containing the fourth structural portion 320 to have a larger overlap area with the fourth structural portion 320. This further increases the overlap area between the first and second terminals, further reducing the parasitic inductance of the power module.

[0079] In some embodiments, the first structural portion 210 and the third structural portion 310 may be on the same plane.

[0080] Continue to refer to Figure 2Optionally, the first structural portion 210 extends in a first direction x from its connection point with the second structural portion 220, and the third structural portion 310 extends in the first direction x from its connection point with the fourth structural portion 320. This allows the first structural portion 210 to extend on the surface of the power module body 100, providing a larger contact surface and enabling effective connection between the first structural portion 210 and the power module body 100. Similarly, the third structural portion 310 extends on the surface of the power module body 100, providing a larger contact surface and enabling effective connection between the third structural portion 310 and the power module body 100. Figure 2 Taking the illustrated example, the first structural portion 210 extends to the right from its connection point with the second structural portion 220, and the third structural portion 310 extends to the right from its connection point with the fourth structural portion 320, instead of one extending to the right and the other to the left. That is, the first structural portion 210 and the third structural portion 310 extend in the same direction. This saves space and allows the second structural portion 220 and the fourth structural portion 320 to be closer together, thereby further reducing the parasitic inductance at the locations of the second structural portion 220 and the fourth structural portion 320.

[0081] Figure 3 This is a top view of a power module provided in an embodiment of the present invention, with reference to... Figure 3 Optionally, in the power module, the first terminal includes at least two first structural parts 210, and the second terminal includes at least two third structural parts 310. The first structural parts 210 and the third structural parts 310 are alternately arranged along the second direction y, which intersects the first direction x.

[0082] Specifically, the third structural portion 310 can extend from the position where it is connected to the fourth structural portion 320 along the first direction x, and extend to a position that protrudes from the second structural portion 220, such that the third structural portion 310 is located between adjacent first structural portions 210; the first structural portion 210 can extend from the position where it is connected to the second structural portion 220 along the first direction x, and extend to a position that protrudes from the fourth structural portion 320, such that the first structural portion 210 is located between adjacent third structural portions 310.

[0083] The first structural portion 210 and the third structural portion 310 are alternately arranged along the second direction y. On the one hand, this allows the first structural portion 210 and the third structural portion 310 to occupy less space on the power module body 100 along the first direction x, resulting in a smaller size of the power module body 100 along the first direction x and improving the integration of the power module. On the other hand, the alternating arrangement of the first structural portion 210 and the third structural portion 310 along the second direction y allows the first terminal and the second terminal to transmit current evenly through the first structural portion 210 and the second structural portion 220 respectively, which is beneficial to improving the performance of the power module.

[0084] Optionally, the second structural portion 220 extends in a third direction z1 from the position connected to the first structural portion 210, and the fourth structural portion 320 extends in a fourth direction z2 from the position connected to the third structural portion 310. The extension distance h1 of the second structural portion 220 and the extension distance h2 of the fourth structural portion 320 are not equal.

[0085] The vertical distance between the first end of the second structural portion 220 and the first structural portion 210 is not equal to the vertical distance between the first end of the fourth structural portion 320 and the first structural portion 210. The first end of the second structural portion 220 is the end of the second structural portion 220 furthest from the first structural portion 210, and the first end of the fourth structural portion 320 is the end of the fourth structural portion 320 furthest from the third structural portion 310. Specifically, because the first and second terminals need to be connected to the power supply respectively, the extension distance h1 of the second structural portion 220 and the extension distance h2 of the fourth structural portion 320 are set to be unequal to facilitate the connection of the second and fourth structural portions 220 to the power supply. In some embodiments, the surface of the second structural portion 220 away from the power body and the surface of the fourth structural portion 320 away from the power module body 100 are in different planes.

[0086] In some embodiments, the third direction z1 and the fourth direction z2 are the same, making the second structural portion 220 and the fourth structural portion 320 parallel, so that the orthographic projection of the second structural portion 220 on the plane where the fourth structural portion 320 is located has a large overlapping area with the fourth structural portion 320, thereby reducing parasitic inductance.

[0087] Figure 4 This is a schematic diagram of another power module provided in an embodiment of the present invention, for reference. Figure 4 Optionally, the first end part further includes a fifth structural part 230, which is connected to the second structural part 220; the second end part further includes a sixth structural part 330, which is connected to the fourth structural part 320; the fifth structural part 230 and the sixth structural part 330 are located in different planes.

[0088] Combined with appendix Figure 4 , 11It can be seen that the fifth structural part 230 and the sixth structural part 330 are sheet-like structures, each corresponding to the plane in which they are located.

[0089] Specifically, the first and second terminals need to be connected to the power supply, with one terminal connected to the positive terminal and the other to the negative terminal. By positioning the fifth structural part 230 and the sixth structural part 330 on different planes, it is convenient for them to connect to the power supply, preventing short circuits and ensuring the reliability of the power module. Figure 2 and Figure 4 When the extension distance h1 of the second structural part 220 is not equal to the extension distance h2 of the fourth structural part 320, the fifth structural part 230 and the sixth structural part 330 can be stacked. For example, the projection of the fifth structural part 230 onto the plane where the sixth structural part 330 is located overlaps with the sixth structural part 330, thereby reducing the parasitic inductance at the positions of the fifth structural part 230 and the sixth structural part 330, further reducing the overall parasitic inductance of the power module, and improving the performance of the power module.

[0090] Optionally, the fifth structural portion 230 extends in a fifth direction u1 from its connection point with the second structural portion 220, and the sixth structural portion 330 extends in a fifth direction u1 from its connection point with the fourth structural portion 320. This arrangement makes the planes containing the fifth structural portion 230 and the sixth structural portion 330 parallel, and in some embodiments, the orthographic projection of the sixth structural portion 330 onto the plane containing the fifth structural portion 230 at least partially overlaps with the fifth structural portion 230. This reduces the parasitic inductance at both the fifth and sixth structural portions 230, further reducing the overall parasitic inductance of the power module and improving its performance.

[0091] Optionally, the fifth structural portion 230 is connected to the first structural portion 210 via the second structural portion 220, with the second structural portion 220 located between the fifth structural portion 230 and the first structural portion 210. In some embodiments, the first structural portion 210, the second structural portion 220, and the fifth structural portion 230 are an integral structure. Optionally, the sixth structural portion 330 is connected to the third structural portion 310 via the fourth structural portion 320, with the fourth structural portion 320 located between the sixth structural portion 330 and the third structural portion 310. In some embodiments, the third structural portion 310, the fourth structural portion 320, and the sixth structural portion 330 are an integral structure. By providing that the first terminal includes the fifth structural portion 230, the second terminal includes the sixth structural portion 330, and the orthographic projection of the sixth structural portion 330 onto the plane containing the fifth structural portion 230 at least partially overlaps with the fifth structural portion 230, the overlap area of ​​the first and second terminal can be increased, thereby further reducing the parasitic inductance of the power module. In some embodiments, the overlapping area of ​​the orthographic projection of the sixth structural part 330 onto the plane where the fifth structural part 230 is located and the fifth structural part 230 accounts for more than 50% of the total projected area of ​​the sixth structural part 330.

[0092] Continue to refer to Figure 4 Optionally, the first terminal further includes a seventh structural portion 240, which is connected to the fifth structural portion 230. The second terminal further includes an eighth structural portion 340, which is connected to the sixth structural portion 330. The eighth structural portion 340 and the seventh structural portion 240 are on different planes, and the orthographic projection of the eighth structural portion 340 onto the plane containing the seventh structural portion 240 at least partially overlaps with the seventh structural portion 240. This arrangement can further increase the overlap area of ​​the first and second terminals and further reduce parasitic inductance. In some embodiments, the plane containing the seventh structural portion 240 and the plane containing the eighth structural portion 340 are parallel. In some embodiments, the plane containing the seventh structural portion 240 is parallel to the plane containing the second structural portion 220, and the plane containing the eighth structural portion 340 is parallel to the plane containing the fourth structural portion 320. Optionally, the first terminal is connected to the first terminal of the power supply through the seventh structural portion 240, and the second terminal is connected to the second terminal of the power supply through the eighth structural portion 340.

[0093] Figure 5 This is a cross-sectional view of a power module provided in an embodiment of the present invention. Figure 6 A schematic diagram of a portion of the structure in the first connecting layer. Figure 7 A structural diagram of a portion of the second connecting layer is shown in the reference. Figures 1-7Optionally, the power module body 100 includes a first connection layer 120 and a second connection layer 130. The first connection layer 120 includes a first welding area 123 corresponding to the first structural part 210, and the first structural part 210 is connected to the first connection layer 120 in the first welding area 123. The second connection layer 130 includes a second welding area 133 corresponding to the third structural part 310, and the third structural part 310 is connected to the second connection layer 130 in the second welding area 133.

[0094] In some embodiments, the first structural part 210 and the first welding area 123 may have a one-to-one correspondence. In other embodiments, the first structural part 210 and the first welding area 123 may have a one-to-many or many-to-one correspondence. The embodiments of the present invention do not make specific limitations here.

[0095] In this embodiment, the first structural portion 210 and the first connecting layer 120 are connected in a corresponding first soldering area 123. In some embodiments, the first structural portion 210 and the first connecting layer 120 are directly soldered. In other embodiments, a first pad 125 connected to the first connecting layer 120 can be provided in the first soldering area 123. The first structural portion 210 is connected to the first connecting layer 120 by soldering to the first pad 125 in the first soldering area 123. This makes it easier to connect the first structural portion 210 and the first connecting layer 120. Optionally, the first pad 125 includes a conductive metal block, such as a copper block, wherein the thickness of the first pad 125 is greater than the thickness of the first connecting layer 120.

[0096] The third structural portion 310 is connected to the second connecting layer 130 in the corresponding second welding area 133. In some embodiments, the third structural portion 310 is directly welded to the second connecting layer 130. In other embodiments, a second pad 135 connected to the second connecting layer 130 can be provided in the second welding area 133. The third structural portion 310 is then welded to the second pad 135 in the second welding area 133, thus achieving the connection between the third structural portion 310 and the second connecting layer 130. This makes the connection between the third structural portion 310 and the second connecting layer 130 easier to achieve. Optionally, the second pad 135 includes a conductive metal block, such as a copper block, wherein the thickness of the second pad 135 is greater than the thickness of the second connecting layer 130.

[0097] Optionally, the first connecting layer 120 further includes a first hollow area 124 corresponding to the first welding area 123; the second connecting layer 130 is provided with a second hollow area corresponding to the second welding area 133. Figure 6 (Not shown in the image).

[0098] Optionally, the area of ​​the first cutout area 124 is less than or equal to the area of ​​the first soldering area 123, and the orthographic projection of the first solder pad 125 on the first connection layer overlaps with the first cutout area 124. (See reference) Figures 1-6 In some embodiments, the first pad 125 is located on the side of the first connection layer 120 away from the first structural portion 210. In this case, the first cutout area 124 can expose the first pad 125, thereby facilitating the soldering of the first structural portion 210 and the first pad 125 at the location of the first cutout area 124. In other embodiments, the first pad 125 is located on the side of the first connection layer 120 closer to the first structural portion 210.

[0099] Optionally, the area of ​​the second cutout area is less than or equal to the area of ​​the second soldering area 133. In some embodiments, the second solder pad 135 is located on the side of the second connection layer 130 away from the second structural portion 310. In this case, the second cutout area can expose the second solder pad 135, thereby facilitating the soldering of the third structural portion 310 and the second solder pad 135 at the location of the second cutout area. In other embodiments, the second solder pad 135 is located on the side of the second connection layer 130 closer to the third structural portion 310.

[0100] Optionally, the first connection layer 120 is provided with a third cutout area corresponding to the second welding area 133, and / or, the second connection layer 130 is provided with a fourth cutout area 134 corresponding to the first welding area 123. Optionally, the power module further includes a power device layer 110, which is located between the first connection layer 120 and the second connection layer 130. Specifically, as shown... Figures 2-7 As shown, when the first connection layer 120 is located on the side of the power device layer 110 away from the first and second terminals, and the second connection layer 130 is located on the side of the power device layer 110 close to the first and second terminals, the second connection layer 130 is provided with a fourth cutout area 134 corresponding to the first soldering area 123. The fourth cutout area 134 exposes the first solder pad 125, thereby facilitating the soldering of the first structural part 210 to the first solder pad 125. For example, the first terminal passes through the fourth cutout area 134 to solder to the first solder pad 125.

[0101] With the first connection layer 120 located on the side of the power device layer 110 close to the first and second terminals, and the second connection layer 130 located on the side of the power device layer 110 away from the first and second terminals, a third cutout area corresponding to the second soldering area 133 is provided on the first connection layer 120. The third cutout area exposes the second solder pad 135, thereby facilitating the soldering of the third structural part 310 to the second solder pad 135. For example, the second terminal passes through the third cutout area and is soldered to the second solder pad 135.

[0102] Continue to refer to Figures 5-7Optionally, the power device layer 110 is provided with at least one bridge arm, which includes an upper bridge arm 111 and a lower bridge arm 112. The first end of the upper bridge arm 111 is connected to the first connection layer 120, and the second end of the upper bridge arm 111 is connected to the first end of the corresponding lower bridge arm 112. Figure 5 As shown in the figure, the connection between the second end of the upper bridge arm 111 and the first end of the corresponding lower bridge arm 112 can be achieved through the conductive layer in the power module body 100, and the second end of the lower bridge arm 112 is connected to the second connection layer 130.

[0103] The first connection layer 120 and the second connection layer 130 each comprise a conductive material, such as copper. The upper bridge arm 111 includes at least one power chip, which may include a switching transistor. When the upper bridge arm 111 includes at least two power chips, these chips are connected in parallel to increase current carrying capacity. Similarly, the lower bridge arm 112 includes at least one power chip, which may include a switching transistor. When the lower bridge arm 112 includes at least two power chips, these chips are connected in parallel to increase current carrying capacity. The first connection layer 120 enables electrical connection between the upper bridge arm 111 and the first terminal; the second connection layer 130 enables electrical connection between the lower bridge arm 112 and the second terminal. The connection between the upper bridge arm 111 and the first connection layer 120 can be achieved via vias, and the connection between the lower bridge arm 112 and the second connection layer 130 can also be achieved via vias.

[0104] According to embodiments of this application, both the upper bridge arm 111 and the lower bridge arm 112 may include a circuit structure formed by an active switching chip and a passive freewheeling chip connected in parallel. The active switching chip includes a metal-oxide-semiconductor field-effect transistor (MOSFET), an insulated-gate bipolar transistor (IGBT), a silicon carbide field-effect transistor (SiC MOSFET), a gallium nitride field-effect transistor (GaNFET), and a bipolar junction transistor (BJT). In some alternative embodiments, the passive freewheeling chip includes a diode, such as an FRD or a Schottky diode. It should be understood that the diode provided in the embodiments of this application may be a silicon diode or a silicon carbide diode.

[0105] In some embodiments, the power module body 100 includes an upper bridge arm 111 and a lower bridge arm 112 corresponding to the three-phase drive bridge arms, respectively; Reference Figure 5 and Figure 6 Optionally, the first connection layer 120 includes a first connection portion 121 that is connected to the upper bridge arm 111 in a one-to-one correspondence, and the orthographic projection of the upper bridge arm 111 on the first connection layer 120 is at least partially located in the corresponding first connection portion 121; the first connection layer 120 also includes a second connection portion 122, and the second connection portion 122 is at least disposed between adjacent first connection portions 121.

[0106] Optionally, along the first direction x, the lower bridge arm 112 of the same phase drive bridge arm is located on one side of the upper bridge arm 111. Along the second direction y, the second connection portion 122 is at least disposed between adjacent first connection portions 121. This arrangement allows the second connection portion 122 between adjacent phase drive bridge arms to transmit current, increasing the current transmission path and further reducing parasitic inductance.

[0107] Figure 8 This is a schematic diagram of another power module provided in an embodiment of the present invention. Figure 8 The diagram schematically illustrates the connection structure 140 of the upper bridge arm in the second connection layer. The upper bridge arm 111 can be connected to the lower bridge arm 112 via the corresponding connection structure 140. (Reference) Figures 4-7 Optionally, in some embodiments, the second connection layer 130 includes a third connection portion 131 that is connected to the lower bridge arm 112 in a one-to-one correspondence, and the orthographic projection of the lower bridge arm 112 on the second connection layer 130 is at least partially located in the third connection portion 131; the third connection layer also includes a fourth connection portion 132, which is at least disposed between adjacent third connection portions 131.

[0108] Optionally, along the second direction y, the fourth connection portion 132 is at least disposed between adjacent third connection portions 131. This arrangement allows the fourth connection portion 132 between adjacent phase drive bridge arms to transmit current, increasing the current transmission path and further reducing parasitic inductance.

[0109] Figure 9 This is a structural diagram of a power module in related technologies, for reference. Figure 9 In related technologies, the first welding area 123 and the second welding area are on the same straight line, which makes it impossible to stack the copper busbar (i.e., the first terminal and the second terminal) connecting the power module body and the bus capacitor. For example, in the second and fourth structural parts corresponding to the embodiments of the present invention, stacking cannot be achieved in some positions, resulting in a large parasitic inductance.

[0110] Figure 10 This is a schematic diagram of another power module provided in an embodiment of the present invention, for reference. Figure 10In some embodiments of the present invention, the first welding area 123 and the second welding area 133 are misaligned along the first direction x, and the first welding area 123 and the second welding area 133 are arranged alternately along the second direction y, and the first direction x and the second direction y intersect.

[0111] like Figure 10 As shown, the power module includes a first edge L1 extending along a second direction y, and a first welding area 123 and a second welding area 133 disposed close to the first edge L1. Along the first direction x, the first welding area 123 and the second welding area 133 are misaligned, meaning that the distance between the first welding area 123 and the first edge L1 is not equal to the distance between the second welding area 133 and the first edge L1. In some embodiments, the distance between the first welding area 123 and the first edge L1 is equal to the perpendicular distance between the point on the first welding area 123 closest to the first edge L1 and the first edge L1; the distance between the second welding area 133 and the first edge L1 is equal to the perpendicular distance between the point on the second welding area 133 closest to the first edge L1 and the first edge L1. For example, the first welding area 123 includes a second edge L2 extending along the second direction y, and the second welding area 133 includes a second edge L3 extending along the second direction y. The distance between the second edge L2 and the first edge L1 is not equal to the distance between the third edge L3 and the first edge L1.

[0112] By misaligning the first welding area 123 and the second welding area 133 along the first direction x, the first structural part 210 and the third structural part 310 can be misaligned along the first direction x. This allows the second structural part 220 and the fourth structural part 320 to be stacked, significantly reducing the parasitic inductance of the second structural part 220 and the fourth structural part 320, thereby reducing the parasitic inductance of the entire system. The first structural part 210 and the third structural part 310 are arranged along the second direction y.

[0113] In addition, by setting the first welding area 123 and the second welding area 133 to be misaligned, compared to Figure 9 When there is no misalignment between the first welding area 123 and the second welding area 133, the structure that achieves misalignment between the second structural part 210 and the fourth structural part 240 can increase the welding area between the first structural part 210 and the first pad, as well as the welding area between the third structural part 310 and the second pad. The larger the welding area, the smaller the parasitic inductance. Therefore, the structure that has misalignment between the first welding area 123 and the second welding area 133 can further reduce the parasitic inductance of the power module and improve the performance of the power module.

[0114] Optionally, one of the first direction x and the second direction y is the length direction of the power module body, and the other is the width direction of the power module body.

[0115] Optionally, the first connection layer includes at least two first soldering areas 123, and the second connection layer includes at least two second soldering areas 133. Along the second direction y, at least two first soldering areas 123 and at least two second soldering areas 133 are in a straight line. This saves space in the first direction x, which is beneficial for improving the integration of the power module.

[0116] Optionally, the first end includes at least two first structural portions 210, each of which is connected by a second structural portion 220; and / or, the second end includes at least two third structural portions 310, each of which is connected by a fourth structural portion 320.

[0117] For example, when the power module body includes three bridge arms, the first structural part 210 corresponding to each bridge arm can be connected into a whole by a second structural part 220, and the third structural part 310 corresponding to each bridge arm can be connected into a whole by a fourth structural part 320, thereby increasing the current flow area and further reducing the parasitic inductance of the power module.

[0118] The second structural portion 220 can be a continuous structure along the second direction y. Optionally, the second structural portion 220 extends along the second direction y, and multiple first structural portions 210 are connected in the extension path of the second structural portion 220, thus ensuring that the second structural portion 220 has a large area. The fourth structural portion 320 can be a continuous structure along the second direction y. Optionally, the fourth structural portion 320 extends along the second direction y, and multiple third structural portions 310 are connected in the extension path of the fourth structural portion 320, thus ensuring that the fourth structural portion 320 has a large area. With the above arrangement, the second structural portion 220 and the fourth structural portion 320 can have a large overlap area, reducing the parasitic inductance of the power module.

[0119] This invention also provides a motor controller. Figure 11 This is a schematic diagram of the structure of a motor controller provided in an embodiment of the present invention, for reference. Figure 11 The motor controller includes the power module of any of the above embodiments of the present invention. Optionally, the motor controller further includes a capacitor C0 and a power supply 20, which are connected in parallel. A first terminal is connected to a first terminal of the power supply 20, and a second terminal is connected to a second terminal of the power supply 20. The motor controller can be applied in a vehicle. The output terminal of the motor controller can be connected to a motor, wherein the common connection terminal of the upper axle arm 111 and the lower axle arm 112 in the power module body 100 serves as the output terminal of the motor controller.

[0120] The motor controller of this invention includes the power module of any of the above embodiments of this invention and has the beneficial effects of the power module of any of the above embodiments of this invention.

[0121] This invention also provides an electric drive assembly, including a motor controller according to any embodiment of this invention.

[0122] This invention also provides a vehicle including an electric drive assembly according to any embodiment of the invention.

[0123] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0124] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A power module, characterized in that, It includes a power module body, a first terminal and a second terminal, wherein the first terminal includes a second structural part and the second terminal includes a fourth structural part; The plane containing the second structural part intersects with the plane containing the power module body, and the plane containing the fourth structural part intersects with the plane containing the power module body. The second structural part and the fourth structural part are located on different planes.

2. The power module according to claim 1, characterized in that, The projection of the second structural part onto the plane where the fourth structural part is located at least partially overlaps with the fourth structural part.

3. The power module according to claim 1, characterized in that, Both the second structural part and the fourth structural part are sheet-like structures.

4. The power module according to claim 1, characterized in that, Both the first terminal and the second terminal are DC terminals.

5. The power module according to any one of claims 1-4, characterized in that, The plane containing the second structural part is parallel to the plane containing the fourth structural part.

6. The power module according to any one of claims 1-5, characterized in that, The first extreme terminal includes a first structural portion connected to the second structural portion, the second extreme terminal includes a third structural portion connected to the fourth structural portion, the plane containing the first structural portion intersects with the second structural portion, the plane containing the third structural portion intersects with the fourth structural portion, the first structural portion is connected to the power module body, and the third structural portion is connected to the power module body.

7. The power module according to claim 6, characterized in that, The first structural part is welded to the power module body, and / or the third structural part is welded to the power module body.

8. The power module according to claim 6 or 7, characterized in that, The plane containing the first structural part is parallel to the plane containing the third structural part.

9. The power module according to claim 5, characterized in that, The distance between the second and fourth structural parts is 1mm-50mm.

10. The power module according to any one of claims 6-9, characterized in that, The first structural portion extends in a first direction from the position where it is connected to the second structural portion, and the third structural portion extends in the first direction from the position where it is connected to the fourth structural portion.

11. The power module according to claim 10, characterized in that, The first end portion includes at least two first structural portions, and the second end portion includes at least two third structural portions. The first structural portions and the third structural portions are alternately arranged along a second direction, which intersects with the first direction.

12. The power module according to any one of claims 6-11, characterized in that, The second structural part extends in a third direction from the position where it is connected to the first structural part. The fourth structural part extends in a fourth direction from the position where it is connected to the third structural part. The extension distance of the second structural part is not equal to the extension distance of the fourth structural part.

13. The power module according to claim 12, characterized in that, The third direction is the same as the fourth direction.

14. The power module according to claim 12, characterized in that, The first extreme terminal further includes a fifth structural portion, which is connected to the second structural portion; the second extreme terminal further includes a sixth structural portion, which is connected to the fourth structural portion. The fifth structural part and the sixth structural part are located on different planes.

15. The power module according to claim 14, characterized in that, The fifth structural part extends in a fifth direction from the connection position with the second structural part, and the sixth structural part extends in a fifth direction from the connection position with the fourth structural part.

16. The power module according to any one of claims 7-15, characterized in that, The power module body includes a first connection layer and a second connection layer. The first connection layer includes a first welding area corresponding to the first structural part, and the first structural part is connected to the first connection layer in the first welding area. The second connection layer includes a second welding area corresponding to the third structural part, and the third structural part is connected to the second connection layer in the second welding area.

17. The power module according to claim 16, characterized in that, The first connecting layer also includes a first hollow area corresponding to the first welding area; The second connecting layer is provided with a second hollow area corresponding to the second welding area.

18. The power module according to claim 16 or 17, characterized in that, The first connecting layer is provided with a third cutout area corresponding to the second welding area, and / or, The second connecting layer is provided with a fourth hollow area corresponding to the first welding area.

19. The power module according to any one of claims 16-18, characterized in that, The power module further includes a power device layer located between the first connection layer and the second connection layer. The power device layer has at least one bridge arm, which includes an upper bridge arm and a lower bridge arm. The first end of the upper bridge arm is connected to the first connection layer, the second end of the upper bridge arm is connected to the first end of the corresponding lower bridge arm, and the second end of the lower bridge arm is connected to the second connection layer.

20. The power module according to any one of claims 16-18, characterized in that, Along the first direction, the first welding area and the second welding area are misaligned, and the first welding area and the second welding area are arranged alternately along the second direction, and the first direction and the second direction intersect.

21. The power module according to any one of claims 16-18, characterized in that, Along the first direction, the first structural part and the third structural part are misaligned.

22. The power module according to any one of claims 6-21, characterized in that, Each of the first structural parts is connected by a second structural part; And / or, each of the third structural parts is connected through a fourth structural part.

23. A motor controller, characterized in that, Includes the power module as described in any one of claims 1-22.

24. An electric drive assembly, characterized in that, Includes the motor controller as described in claim 23.

25. A vehicle, characterized in that, Includes the electric drive assembly as described in claim 24.

Images