Vehicle power module with signal terminals welded through ultrasonic waves

Abstract

The utility model provides a vehicle power module with signal terminals welded through ultrasonic waves, which relates to the technical field of power modules and comprises a plurality of insulating substrates welded on a heat dissipation copper substrate, at least one IGBT (insulated gate bipolar transistor) chip and at least one diode chip welded on a conductive copper layer of each insulating substrate. The front surfaces of the IGBT chip and the diode chip are bonded in the power circuit etching region of the insulating substrate through binding wires; a plurality of power terminals, wherein each power terminal is welded on the conductive copper layer of the insulating substrate; and the signal terminals are integrally welded on the conductive copper layer of the insulating substrate through ultrasonic waves. The beneficial effects of the utility model are that the signal terminal is inserted in the welding pedestal, and an ultrasonic welding connection technology is employed, thereby improving the connection reliability, stability and heat dissipation performance of the IGBT module, solving the defects of a conventional IGBT module in the aspects of connection and heat dissipation, and providing a powerful technical support for the sustainable development of a new energy automobile.

Description

TECHNICAL FIELD

[0001] The utility model relates to power module technical field especially through ultrasonic wave welding signal terminal's vehicle power module. BACKGROUND

[0002] In the field of new energy vehicles, insulated gate bipolar transistors (IGBT) modules are increasingly widely used, becoming an important force to promote high-quality economic development. However, with the continuous progress of technology and the continuous improvement of demand, traditional IGBT modules gradually reveal many limitations in structure and circuit connection. In particular, the connection method of traditional signal terminals, such as plug-in parts or welding, has hidden dangers such as loose connection, easy loosening, poor contact, and challenges to the transmission quality of signals and the stability of the system. In addition, the internal structure of traditional vehicle power modules is complex, with poor maintainability and repairability, and insufficient heat dissipation performance, making it difficult to meet the stringent requirements of new energy vehicles under high temperature, high power, and high frequency switching operation. SUMMARY

[0003] In view of the problems existing in the prior art, the utility model provides a vehicle power module with signal terminals welded by ultrasonic waves, comprising:

[0004] A heat dissipation copper substrate is provided, and a plurality of insulating substrates are welded on the heat dissipation copper substrate. Each of the insulating substrates has at least one IGBT chip and a diode chip welded on the conductive copper layer, and the front surface of the IGBT chip and the diode chip is bonded to the power circuit etching area in the conductive copper layer of the insulating substrate by a bonding wire.

[0005] A plurality of power terminals are welded on the conductive copper layer of the insulating substrate.

[0006] A plurality of signal terminals are integrally welded on the conductive copper layer of the insulating substrate by ultrasonic welding.

[0007] Preferably, the signal terminal comprises:

[0008] A welding base is welded on the conductive copper layer of the insulating substrate by ultrasonic welding.

[0009] A rectangular straight needle is inserted and assembled in the welding base with interference fit and connected by ultrasonic welding.

[0010] Preferably, the welding base comprises a base body, and a terminal connector is provided on the surface of the base body and integrally formed with the base body.

[0011] Preferably, the terminal connector is a circular ring-shaped column, and the straight needle is inserted and ultrasonically welded in the inner ring of the terminal connector.

[0012] Preferably, the binding wire is an aluminum wire, or a copper wire, or an alloy wire.

[0013] Preferably, the conductive copper layer of the insulating substrate and the IGBT chip are connected by soldering with a tin-based alloy material, and the conductive copper layer of the insulating substrate and the diode chip are connected by soldering with a tin-based alloy material.

[0014] Preferably, the base body is a cylinder, the cross-sectional diameter of the base body is 1.5-3mm, and the thickness of the base body is 0.3-0.6mm.

[0015] Preferably, the outer diameter of the terminal connector is 1.0-1.5mm, and the inner diameter of the terminal connector is 0.7-0.8mm.

[0016] Preferably, the edge length of the rectangular straight pin is 0.6-0.7mm.

[0017] Preferably, the surface of the signal terminal is gold-plated.

[0018] The above technical scheme has the following advantages or beneficial effects:

[0019] The signal terminal connector in the vehicle power module is welded in the welding base and is welded to the conductive copper layer of the insulating substrate by ultrasonic welding, so as to realize electrical connection and prevent falling off. The signal terminal adopting the ultrasonic welding process aims to improve the connection reliability, stability and heat dissipation performance of the IGBT module, solves the deficiencies of the traditional IGBT module in connection and heat dissipation, and provides strong technical support for the continuous development of new energy vehicles. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 In a preferred embodiment of the present application, a schematic diagram of the overall structure of the vehicle power module with the signal terminal welded by ultrasonic welding is shown.

[0021] Figure 2 In a preferred embodiment of the present application, a schematic diagram of the internal structure of the vehicle power module with the signal terminal welded by ultrasonic welding is shown.

[0022] Figure 3 In a preferred embodiment of the present application, a schematic diagram of the internal structure of the vehicle power module with the signal terminal welded by ultrasonic welding is shown. Figure 2 An enlarged schematic diagram of the A area in the middle. DETAILED DESCRIPTION

[0023] The present application will be described in detail below with reference to the drawings and specific embodiments. The present application is not limited to this embodiment, and other embodiments can also belong to the scope of the present application as long as they meet the main idea of the present application.

[0024] The preferable embodiment of the utility model discloses a vehicle power module through ultrasonic welding signal terminal based on the above -mentioned problems existing in prior art, as shown in Figure 1 And Figure 2 As shown in:

[0025] The heat dissipation copper substrate 1 is welded with a plurality of insulating substrates 2, at least one IGBT chip 3 and diode chip 4 are welded on the conductive copper layer of each insulating substrate 2, and the front surface of the IGBT chip 3 and diode chip 4 is bonded in the power circuit etching area of the conductive copper layer of the insulating substrate 2 through the binding wire 5.

[0026] A plurality of power terminals 6 are welded on the conductive copper layer of the insulating substrate 2.

[0027] A plurality of signal terminals 7 are integrally welded on the conductive copper layer of the insulating substrate 2 through ultrasonic welding.

[0028] Specifically, as shown in Figure 1 And Figure 2 The vehicle power module is further covered with a shell 9, and each signal terminal 7 is exposed from the hole of the shell 9; the signal terminal 7 in the vehicle power module is plugged in the welding base 8 and is welded on the conductive copper layer of the insulating substrate through ultrasonic welding, electrical connection is realized, and the signal terminal 7 is not easy to fall off, has process reliability, improves the welding stability of the power module, and improves the service life.

[0029] As shown in Figure 3 The signal terminal 7 comprises:

[0030] The welding base 8 is welded on the conductive copper layer of the insulating substrate 2 through ultrasonic welding.

[0031] The rectangular straight needle 71 is assembled in the welding base 8 through interference and is connected through ultrasonic welding.

[0032] The welding base 8 comprises:

[0033] The base body 81 is provided with a terminal connector 82 on the surface, and the terminal connector 82 is integrally formed with the base body 81.

[0034] In the preferable embodiment of the utility model, the terminal connector 81 is a circular ring column, and the rectangular straight needle 71 is inserted and ultrasonically welded in the inner ring of the terminal connector 81.

[0035] Specifically, in this embodiment, the rectangular straight needle 71 is assembled in the welding base 8 by interference fitting and is electrically connected by ultrasonic welding, and the signal terminal 7 is integrally welded on the conductive copper layer of the insulating substrate 2 by ultrasonic welding, which improves the process reliability and enhances the welding reliability of the power module and prolongs the service life.

[0036] In the preferred embodiment of the utility model, the binding wire 5 is an aluminum wire, a copper wire or an alloy wire.

[0037] In the preferred embodiment of the utility model, the conductive copper layer of the insulating substrate 2 and the IGBT chip 3 are connected by tin-based alloy welding, and the conductive copper layer of the insulating substrate 2 and the diode chip 4 are connected by tin-based alloy welding.

[0038] Specifically, the tin-based alloy material generally has good electrical conductivity and thermal conductivity, which is crucial for the heat dissipation and electrical performance of power semiconductor devices such as IGBT and diode. The melting point of tin-based alloy is generally low, which means that the required temperature during welding is relatively low, thereby reducing the potential damage to the chips and other components caused by high temperature. The tin-based alloy welding joint generally has high strength, which can ensure the firm connection between the chip and the conductive copper layer, improve the reliability and durability of the entire component.

[0039] In the preferred embodiment of the utility model, the base body 81 is a cylinder, the cross-sectional diameter of the base body 81 is 1.5-3mm, and the thickness of the base body 81 is 0.3-0.6mm.

[0040] In the preferred embodiment of the utility model, the outer diameter of the terminal connector 82 is 1.0-1.5mm, and the inner diameter of the terminal connector 82 is 0.7-0.8mm.

[0041] In the preferred embodiment of the utility model, the width of the rectangular straight needle 71 is 0.6-0.7mm.

[0042] Specifically, in this embodiment, as shown in Figure 3 the rectangular straight needle 71 is a rectangular straight needle with a square cross section, and the side length is 0.6-0.7mm, so the diagonal is 0.6√2-0.7√2mm, which is slightly larger than the inner diameter of the terminal connector 82, can realize interference fitting assembly, is a non-rigid connection, can absorb buffer, reduces the stress borne by the module.

[0043] In the preferred embodiment of the utility model, the surface of the signal terminal 7 is gold-plated.

[0044] Specifically, the welding base 8 and the rectangular straight needle 71 in the embodiment are made of pure copper or copper alloy material, the surface of the base body 81 and the terminal connector 82 in the welding base 8 is bare copper, and no plating layer is allowed, so as to improve the ultrasonic welding reliability; the surface of the rectangular straight needle 71 is gold-plated, easy to preserve and stable in surface state.

[0045] The above are only the preferred embodiments of the present application, and are not intended to limit the embodiments and protection scope of the present application. For those skilled in the art, it should be realized that any equivalent replacement and obvious change made according to the content of the present application and drawings should be included in the protection scope of the present application.

Claims

1. A vehicle power module with signal terminals welded by ultrasonic welding, characterized in that, include: A heat-dissipating copper substrate, wherein multiple insulating substrates are soldered on the heat-dissipating copper substrate, and at least one IGBT chip and one diode chip are soldered on the conductive copper layer of each insulating substrate, and the front sides of the IGBT chip and the diode chip are bonded to the power circuit etching area in the conductive copper layer of the insulating substrate by bonding wires. Multiple power terminals, each of which is soldered onto the conductive copper layer of the insulating substrate; Multiple signal terminals are provided, and each of the signal terminals is ultrasonically welded onto the conductive copper layer of the insulating substrate.

2. The automotive power module according to claim 1, characterized in that, The signal terminal includes: A welding base, wherein the welding base is ultrasonically welded onto the conductive copper layer of the insulating substrate; A rectangular straight needle is interference-fitted into the welding base and connected by ultrasonic welding.

3. The automotive power module according to claim 2, characterized in that, The welding base includes: a base body, on the surface of which a terminal connector is provided, and the terminal connector is integrally formed with the base body.

4. The automotive power module according to claim 3, characterized in that, The terminal connector is a circular cylinder, and the straight pin is inserted into and ultrasonically welded in the inner ring of the terminal connector.

5. The automotive power module according to claim 1, characterized in that, The binding wire is made of aluminum, copper, or an alloy.

6. The automotive power module according to claim 1, characterized in that, The conductive copper layer of the insulating substrate and the IGBT chip, as well as the conductive copper layer of the insulating substrate and the diode chip, are welded together using a tin-based alloy material.

7. The automotive power module according to claim 3, characterized in that, The base body is a cylinder with a cross-sectional diameter of 1.5-3mm and a thickness of 0.3-0.6mm.

8. The automotive power module according to claim 3, characterized in that, The outer diameter of the terminal connector is 1.0-1.5mm, and the inner diameter of the terminal connector is 0.7-0.8mm.

9. The automotive power module according to claim 2, characterized in that, The side length of the rectangular straight needle is 0.6-0.7 mm.

10. The automotive power module according to claim 1, characterized in that, The surface of the signal terminal is plated with gold.

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